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Global News & Information on the Bulk Materials Handling, Recycling & Quarrying industries Check out the very latest industry news at www.hub-4.com
Issue 25
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In this issue COVER STORY
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NEWS
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UK aggregates industry continues its struggle to replenish reserves
Save ÂŁ000's on tax Further developments for CMS Cepcor Introducing the new look brand Industrial quality recycling Proven products Anaconda appoints second UK dealer RECYCLING
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Terex Finlay 883 Spalek Going for Gold Two new innovations from MB Barton plant buys first Bell loader Ajax equipment screw elevator and hopper CCC Waste takes Terex Finlay 694 From crushing waste glass to cosmetics WASTE SORTING
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Eriez Poker Sort Overbands reduce shredder downtime The best value QUARRYING
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Wordsworth Crushing adds more Hamilton Aggregates show how Frimstone go for lease hire WASHING, SCREENING, PUMPS
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Wopfinger Transportbeton
Nationally, BDS estimates that just 70% of sand and gravel production was replaced with new consents. This is a similar rate to the previous year and continues the trend which has occurred over many years. The national picture looks better in crushed rock. However, this is solely due to one major consent in the south west. If this one scheme is excluded, then BDS calculates that crushed rock producers were able to replace just one in every three tonnes extracted in 2012. The situation was particularly acute in the largest crushed rock producing region - the east midlands - which saw no major consents during 2012. In the industry as a whole, BDS has identified no other consents granted during 2012 for proposals that involved more than an additional 5 million tonnes of reserves.
Flex-Mat3 Weir secures ÂŁ4.4m pump deal Heavy duty trommel DSC Marlin Developments in screening Sykes Pumps launches new pump Analysis equipment BULK MATERIALS HANDLING
The UK aggregates industry continues to be unable to replenish its output with new reserves. Eight out of 10 planning regions failed to replace reserves extracted during 2012. This is despite markets continuing at historically low levels during the year. The industry marketing consultancy, BDS Marketing Research Ltd, estimates that last year, only in Scotland and the south west, were aggregates companies able to fully replenish reserves.
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Over the previous 15 years, BDS believes that only in 2006 has the quarrying industry more than replenished the reserves taken out during the year. In one other year, new consents granted were similar to production. However, in the
other 13 years, the consultancy estimates that consented reserves failed to match production. 'The position looks no better for 2013', said the principal consultant for BDS, Julian Clapp. Applications submitted last year for new crushed rock reserves amounted to just 20 million tonnes. This equates to less than three months' production. The position looks better in sand and gravel, although the figures are boosted by one large outstanding application in the midlands'. This analysis has been prepared by BDS Marketing Research Ltd which has monitored planning applications and consents for new minerals since the consultancy first started in 1989. A monthly BDS report lists planning applications and consents for all new minerals including aggregates, coal and other minerals, and asphalt plants. This is available on an annual subscription. The company also maintains a database of all pits and quarries. This includes details of planning decisions, together with estimates of the outputs and reserves for each pit and quarry in the country. BDS Marketing Research publishes a number of reports on the aggregates, asphalt, ready mixed concrete, concrete products, cement and waste industries. The consultancy also completes over 50 surveys each year that have been commissioned by individual clients. These can relate to new product development, assessing market size, customer research and acquisition appraisals. www.bdsmarketing.co.uk
Wear resistant linings Wet weather provides no barrier Replacement of ribbon mixers The clever option WEIGHING CEMEX UK invests Loadmaster a100 debuts Top safety accreditation
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Cover Story
Introducing the - washing as it should be Terex Systems (TWS) is making final plans to unveil a new innovative washing system, one which is sure to become a global market leader - The AggreSand system. This is the latest edition to an already extensive product portfolio and is due to be officially launched in Quarter 2, 2013. ®AggreSand system aggregate washing and screening with sand processing on a modular chassis. It brings together tried and trusted Terex Washing Systems components in an innovative modular design, setting itself apart from other washing systems in the marketplace. A gap in the market for such a washing evolution was identified following extensive research, part of which was conducted at the Terex Washing Systems first ever product development forums. These involved TWS engineers and sales technicians working with the global distributor network to formulate the concept. Central to the development of the new plant was a modular design, pre-wired and pre-plumbed making it quick and easy to set-up and easy to maintain. The plant also includes a range of other innovative features and designs. Sean Loughran, Director of TWS commented “The AggreSand system will represent the epitome of washing in the marketplace and is a combination of significant enhancements and design changes to existing products as well as the introduction of new pioneering ideas. In our ongoing efforts to meet and exceed customer expectations, the AggreSand system will enable TWS customers to wash a wide range of materials at a high specification and produce up to 5 products.”
AggreSand System Key Features & Benefits H 12 Hopper - TWS designed a new modular hopper feeder with 12m3 in keeping with ever increasing loading shovel sizes in today's modern quarries and sand pits. The H 12 is available with an automatic tipping grid and a 12' two deck vibrating grid complete with variable speed belt feeder, all controlled from the main operator interface and radio control unit. Feed Conveyor - The wide feed conveyor has a direct drive electric motor and gearbox arrangement and will work at a 19oangle when feeding the AggreSand system. The inclined feed conveyor features an innovative sealed wash box at the discharge point to give material a prerinse to pre-condition for screening. The innovative design eliminates splashing at this point and produces an even distribution of material to the full width of the rinsing screen thus utilizing the full screening area. 165R-3 Rinsing Screen - TWS opted for the highly efficient 165R-3 (three deck, two bearing) rinsing screen. The screen's riveted construction reduces the stress associated with welded construction methods. TWS engineers designed this in such a way to isolate all spray bars from any vibration, utilizing high quality rubber gators
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on the mid and bottom decks. Top deck rubber extensions also prevent overspill or splashing from the top deck screen. The 165R-3 gives a true 80ft2(7.54m2) of screening area on all three decks. Each deck has eight individually controlled spray bars fitted with polyurethane fan type spray nozzles. An advanced rolling chute arrangement gives the ability to blend top deck and mid deck overflows as well as mid deck & bottom deck overflows which will prove very useful in construction and demolition recycling applications. The screen is designed to receive standard polyurethane modular screens (woven wire screens option also available) on all decks. Sump Tank - The large capacity split sump tank receives the rinsed fines from the bottom deck screen into either a course or fine compartment. The course side of the tank has a built-in float system to help equalize the levels in both tanks and prevent overflowing. Large inspection doors are included in both tanks as well as butterfly valve drains on both sides. The tank is also fitted with anti-turbulence plates and a pump protection system. Centrifugal Slurry Pumps & Hydrocylones Two centrifugal slurry pumps (Course & Fine) are used to pump material from both sides of the sump tank into two hydrocyclones. The hydrocyclones remove silts and clay (material below 63micron) which are sent to the water treatment plant. The heavier material (above 63micron) exits the bottom of the hydrocyclones into a rubberlined box where blending can take place if required.
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Cover Story 125 Dewatering Screen - The underflow from the hydrocyclones transfers onto a dewatering screen via a discharge box which equally distributes the material across the screen to increase the dewatering screen area. Both materials are dewatered over a 500 micron polyurethane screen to produce two instantly salable grades of sand. The high energy dewatering screen is fitted with two high efficiency counter rotating vibratory motors which remove capillary water to produce two dewatered sands. The rubber lined catchbox under the dewatering screen carries the underflow back to the tank for recirculation through the cyclones.
High Energy Sand Plant
Integrated Conveyors - The AggreSand system has the option of five conveyors, three aggregate and two sand. The 650mm wide conveyors are powered by direct drive electric motors and gearbox arrangements. The 9.3m long conveyors are angled at optimum height for excellent production. The two conveyors have an innovative automated radial wheel drive system that increases stock piling capacity to an amazing 350m3. The
Cutting Edge Control System
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conveyors are fitted with high quality teardrop polyurethane scrapers. The aggregate oversize conveyor has a novel feature whereby it can be placed on either side of the machine in accordance with the customers site set-up/preference. The 4m stock pile height of these conveyors make them ideal for producing generous stock piles or feeding other equipment within the Terex productrange.
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Cover Story Accessible Service Areas - Maintenance and access was of critical importance during the design process of the AggreSand system and this has been achieved through a number of advanced features. There are 600mm wide access platforms on both sides of the machine. This allows easy access to both the rinsing and dewatering screens. All walkways and handrails are galvanized as standard with curved ends and expanded metal floors. The centrifugal slurry pumps are mounted on roll in - roll out tables for ease of access and maintenance. The main feed conveyor section which travels over the aggregate screen is hinged so that it can be raised to allow greater screen access. The rinsing screen has a roll away chute to also allow for easy access to all screen decks. The plant is also fitted with a high pressure retractable wash down hose. If required the spraybars can be easily removed for maintenance purposes. The pumps on the plant are fitted with drains for drainage in frosty conditions to virtually eliminate downtime. The system is with integrated prewired 4x500watt metal halide flood lights controlled via photocell.
Cutting Edge Control System - TWS has developed an advanced and cutting edge user-friendly control system. The AggreSand system will give operators levels of automation and control not previously available on wash plants. TWS has utilized PLC technology which has already been field proven within the wider Terex crushing and screening plants. The control system will provide measurement and control in terms of belt speed, water pressure, pump pressures, etc. This will include full radio control of all critical functions such as auto start/stop, feeder start/stop and speed control. Full telemetry is supplied as an option where all data is sent to the plant owner remotely such as belt tonnages, alarm conditions, run times etc. Easy Set-Up - The AggreSand system encompasses tried and trusted Terex in an innovative modular set up. The AggreSand system is designed specifically to provide quick installation and deployment with one connecting power point and one water feed point for the entire plant. Set up time will typically be one day making the plant ideal for long or short term contracts. The AggreSand system has an economic water requirement and is ideal for coupling to a TWS water treatment plant to recycle this water thus reducing the overall water requirement. The plant was designed to have a small footprint, also reducing the requirement for major ground preparation work. Ease of Transport - All components are designed so they can be easily dismantled and placed into standard 40ft containers, limiting the reassembly time on site with fewer crane lifts required. TWS will officially launch the AggreSand system in Quarter 2, 2013. To find out more or to discuss specific washing requirements, contact us at TWS.Sales@terex.com or visit our dedicated website which provides an overview of the full product offering at www.terex.com/washing www.hub-4.com/directory/15386
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News
Save £'000's on Tax by carefully planning machinery purchases from 01.01.13 but before 01.01.15 “This is a very generous increase that will be warmly welcomed by many small businesses. It is an open invitation to almost all businesses to invest and get a 20% (or more) subsidy for all their plant and machinery investment.” Chartered Institute of Taxation - 5th December 2012. One of the surprises in the 2012 Autumn Statement was a temporary tenfold increase in the Annual Investment Allowance (AIA) from £25,000 to £250,000 for capital expenditure incurred on eligible plant and machinery (new or used but not cars) on/after 1st January 2013 and before 1st January 2015. After this period the AIA is destined to revert back to £25,000. The benefit of an AIA is to accelerate the timing of the tax relief by providing 100% tax relief for qualifying capital expenditure in the accounting period in which the expenditure is actually incurred. This is particularly attractive where the rates of corporation tax are falling; acting promptly may generate higher tax relief before the top rate of 24% falls to 21% from April 2014. The AIA applies to ALL businesses - so for unincorporated businesses paying 40% or more in income tax - the tax relief could be substantially greater. Annual expenditure above the first £250,000 will attract the usual 18% annual Writing Down Allowance in the first year with the balance going in to the pool of allowances for subsequent years. Under normal circumstances it can take up to 12 years to write off 90% of a machine's cost against tax.
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Timing of expenditure is crucial In order to secure the maximum available tax benefit, it is vital that a carefully planned and possibly phased purchase programme takes due regard of the business' financial year end, particularly if the accounting period straddles the January introduction and end dates of the temporarily enhanced AIA. Get the timing and /or the amounts wrong and the business could either miss out on available tax relief or worst still, end up paying far more tax than required. A business with the same accounting period as the tax year would normally be easy to calculate but the January introduction of the AIA creates a straddling period which results in only 3/12ths of £250,000 being eligible for an AIA claim for any expenditure in the first calendar quarter of 2013 i.e. £62,500 instead of £250,000. However, if there is no expenditure in that first quarter then up to £62,500 of potential tax write off will be lost in that accounting year. The flip side of the coin is a business with a calendar financial year ending 31st December. It could spend £250,000 at any time from the 1st January until the end of December 2013 and, given that it makes at least £250,000 of profits during 2013, will be able to write off the whole amount. Different companies with different accounting periods will result in different amounts and different key periods of expenditure. There are further rules relating to the timing of the capital expenditure which can restrict the maximum AIA entitlements. These rules are quite complex and financial advice will be needed from your accountant or Finance Director. Making it easy to understand The table below shows four different financial year end companies and how vital it is to spend the right amount within the right periods in order to maximise the tax benefits. This is particularly important for capital expenditure near the start or the end of the temporary two year enhanced AIA. The easiest scenario to understand is a 31st December financial year-end company which can purchase £250,000 of eligible plant and machinery at any point in its accounting year between January and December. For other accounting periods the scenarios will be more complex but even for these businesses there is a middle period which does not straddle the January 2013 introduction date or the January 2015 end date where the full £250,000 AIA can be claimed. The table makes this clear.
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News
This all sounds very good but what does it mean? Imagine the following scenario: a partnership of a father and his two sons, having made good profits, is belatedly contemplating replacing some machinery, having not purchased any machinery that year. The rapid approach of the 2013/14 tax year end is causing the accountant some concern with the potential of a big income tax bill for his client. Even after claiming all available business expenses, a profit of £250,000 remains, which would attract the 40% income tax rate. The partnership's accounting period matches the tax year. The accountant explains that, if the partnership invests £250,000 in eligible machinery the full £250,000 AIA will apply. He also suggests that there is a great cash flow benefit to be had by using Hire Purchase. Paying a 10% deposit (£25,000) and borrowing £225,000 over three years on a hire purchase agreement equates to a £100,000 outlay in the first year of the acquisition, followed by £75,000 in each of the subsequent years (net of interest charges). The £100,000 expenditure over the first year equals the £100,000 tax bill saved, so HM Revenue & Customs has effectively paid for the partnership's deposit and its first year's HP payments. Not only that, but the partnership has managed its cash flow in an exemplary fashion - claiming the maximum £250,000 AIA but with an outlay of perhaps only £25,000 if they acquired the machinery in the last month of the financial/tax year. Paying £250,000 in cash on day one would only net the same overall tax benefit but would not gain any prizes for cash flow management. As a matter of interest (excuse the pun) any interest paid on the Hire Purchase agreement is also 100% allowable against taxable profits. However, be warned because the above scenario has an accounting period that straddles the 1st January 2013 which means a phased purchasing plan will required to maximise the AIA that can be claimed. If £62,500 is not spent in the first quarter of 2013 then that AIA will be lost forever. Equally only £187,500 AIA is available between April and December 2014 because the AIA will drop to £25,000 from 01.01.15 onwards. Only 3/12ths of the subsequent £25,000 AIA (£6,250) can be claimed in that last quarter so don't leave it until the last quarter to make the purchase. Other factors being equal, if your business is contemplating purchasing eligible machinery there are some strong tax-based and cash flow arguments to justify carefully planned machinery purchases, probably in a phased manner, in order to maximise the tax savings available from this temporary opportunity. Whilst all of the above can only be achieved by businesses making enough profits to offset the capital expenditure via hire purchase (or even cash) there is a financial alternative - leasing. This would be particularly applicable for those businesses not making high enough profits to claim the full AIA but who still want to enjoy the considerable cash flow benefits that leasing can offer. In addition if the business is likely to spend more than £250,000 then, once this amount has been spent, leasing can then re-emerge as the most tax efficient funding method for most businesses. Talk to JCB Finance about the leasing alternatives. JCB Finance is not a tax or financial advisor - always seek advice from your accountant or finance director, because every business' circumstances are different. Businesses should not make investment decisions purely on a tax basis - there should be a compelling business case for the investment.
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Further developments for CMS Cepcor
CMS Cepcor™ has announced that with immediate effect, Baguley Precision Engineers Limited, the wholly owned UK manufacturing subsidiary business of CMS Cepcor™ has been transferred into their Precision Services Division. With recent investment in new premises in Coalville to accommodate a new technical centre, the company has made the decision to transfer all Baguley personnel into the newly formed Precision Services Division; subsequently relocating all machining services from Burton-on-Trent to the new technical centre. The new technical centre represents a substantial investment in new premises, and CNC manufacturing capability, which will further enhance the manufacturing, inspection and repair facilities in Coalville and offers greatly improved manufacturing efficiency for the company.
Our approved facilities include CNC, milling, turning, boring, slotting, grinding, drilling, pressing, welding, co-ordinate measuring, material testing and assembly. Chris Sydenham - Technical Director, commented, “The recent transfer of Baguley into the Precision Services Division and our recent business expansion, will mark the beginning of a new manufacturing chapter for the company which will also provide further opportunities for our supply partners.” The new technical centre (full capacities list available) which will be formally commissioned during Q1 of 2013 is located at Samson Road on Hermitage Industrial Estate in Coalville , Leicestershire. Preferred Supplier Status. Further developments confirm that CMS Cepcor™ has again been awarded preferred supplier status, covering replacement crusher parts and manganese crusher liners and service by Aggregate Industries, a leading player in the UK construction industry. CMS Cepcor™ have held preferred supplier status in the UK since 2006, supplying a wide range of crusher services, crusher repairs, premium replacement crusher spare parts and premium manganese crusher liners.
CMS Cepcor™ were also delighted to confirm that all skilled engineering staff have been retained and further recruitment of skilled CNC operator/programmers is currently underway.
The company is Europe's leading and largest aftermarket manufacturer and supplier of quality replacement crusher spares and service, supplying worldwide to the quarrying, mining, demolition and recycling industries.
Alongside the UK manufacture of crusher, screen, feeder and coating plant spare parts, the company are also experienced machining contractors to the Rail, Power, Water Treatment, Brewery and Oil Exploration (including deep sea, rig head and pipeline) Industries.
CMS Cepcor™ premium manganese steel and alloy crusher liners are independently proven in mining and aggregate production, to achieve, and often exceed the performance of the equivalent original equipment manufacturers' castings. www.hub-4.com/directory/1761
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Introducing the new look Rapid World renowned Rapid International Ltd will officially unveil its new look corporate branding at Bauma International Trade Fair, Munich, on 15-21 April 2013. Customers new and existing can expect the same high levels of expertise and quality they've come to know over the last forty years, with a fresh new look. An important step forward, the new logo refines and modernises the existing logo mark. The new corporate branding reflects both the history and the future of the company at a symbolic time for the organisation, as it welcomes the arrival of the next generation . Mr John Pickering, son of Rapid's late founding partner Mr Bertie Pickering, joined the company recently as Export Sales Manager. With an unrivalled reputation for service and expertise, Rapid's range of mixers and plant for the concrete, construction and environmental industries continues to offer quality engineering and reliability. Ever innovating, Rapid's newest introduction 'Transbatch' , launched in August 2012, offers a compact solution in mobile batching. The roll out of the new logo across all platforms will take some time to filter through and as such there may be some instances where the old logo will be used in the short term. The new brand identity is 'an exciting development for the company' says Mr Jarlath Gilmore, Rapid's Sales & Marketing Director, 'Rapid has undergone fantastic developments in its export markets over the last number of years and this new logo is testament to not only the heritage of the brand but also it's exciting future ahead.'
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Industrial Quality Recycling (IQR) purchase Elme Magnets Industrial Quality Recycling (IQR) have added to their product portfolio by purchasing one Sweden's leading metal separation manufacturers Elme Magnets. The company has been working at the forefront of the electro-mechanical industry since 1955, developing methods and manufacturing machines for environmental and recycling operations. By cooperating closely with customers and end-users we have been able to find technological solutions to a variety of challenges and problems - innovations which in many instances have resulted in patented magnetic products.
“We are very pleased with the additional business opportunities this will help us create. We have been using these products in our own processing facilities since 1985. The close working relationship we have developed and the quality of the products is what we recognise and expect� Thomas Karlstrom Chairman of IQR. www.hub-4.com/directory/8987
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News
Proven products and proven partnership Bell Equipment gains Finlay distribution rights in South Africa South African OEM, Bell Equipment has been granted distribution rights by TerexŽ Finlay for their range of mobile crushing, screening and recycling equipment in South Africa, thereby expanding its strategic alliances with global OEMs and growing the company's product range. Announcing the distribution agreement in Omagh, Northern Ireland earlier this month, Terex Finlay's Sales and Marketing Director, Nigel Irvine said: "Southern Africa is a growing mobile crushing and screening region and we begin our partnership with Bell Equipment as a market leading brand. Through Bell Equipment we have a strong business partner with locations throughout the market place and focused customer support. This offers us a great partner platform to further develop new Finlay equipment sales and also support the large existing population of machines across the region. We look forward to growing our position in the market and developing our partnership." Commenting on the announcement, Bell Equipment Group Chief Executive, Gary Bell said the company is looking forward to growing its partnership with Terex Finlay and is pleased to be able to enhance its product range with the addition of a world class material processing product line. "Our agreement will complement our existing product offering and is in line with our strategy to provide a one-stop shop for first class equipment solutions to our customers throughout Southern Africa�.
The Finlay tracked mobile crusher product line includes jaw, impactor and cone crushers. This range of crushers is internationally renowned for their versatility and flexibility in the reduction and sizing of aggregates for construction materials, mining and also recycling construction waste. The Finlay tracked mobile screener product line comprises of 3-way split heavy duty forward facing, 3-way and 4-way split inclined and 4-way split horizontal screening units. This comprehensive range of tracked mobile machines are proven on a global basis in applications ranging from heavy duty scalping to high precision screening. Continued Bell: "The Finlay range is a good and proven product that is well recognised in the mining, aggregate and recycling sectors. Importantly we are establishing a dedicated team of industry and product specialists to provide sales and service to our screening and crushing customers throughout the territory.
"Our partnership is a natural progression for Bell as we already distribute and support Articulated Dump Trucks, Excavators and Wheel Loaders, which are used extensively in the mining and quarry industries. We are also active in the coal mining industry where several customers make use of mobile crushing and screening equipment. In addition, the new partnership ties in closely with our Bomag range of machines which make use of aggregates supplied from these material processing machines," he added. www.hub-4.com/directory/305
GipoCOMBI RC130FDR
J50 Jaw Crusher
AGGREGATE PROCESSING & RECYCLING LTD - HEDGING LANE, WILNECOTE, TAMWORTH . B77 5EX TEL +44 (0)1827 280139 FAX +44 (0)1827 287770 Email: info@agg-pro.com www.agg-pro.com
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Bosch Rexroth expands into Filtration Market Bosch Rexroth has expanded its product portfolio in the UK market to include its own range of filtration systems. The range expansion is the result of Bosch Rexroth’s acquisition of K & H Eppensteiner GmbH & Co in 2009, one of Europe’s most established filter manufacturers. As a result, the Eppensteiner range of filtration products is now being rebranded Bosch Rexroth and being made available in the UK. The breadth of the range covers all aspects of filtration with high flow rates and several pressure ranges in return and pressure types such as inline, manifold, tank mounted, duplex and all with indication options. They can be applied to a range of applications, from agriculture through to rail, mobile and industrial. The new product portfolio also contains all filter accessories, including filter programs, oil purification, measuring instruments and specific condition monitoring systems. Crucially, the expanded range will include the award winning LE (N) 0040-0400 series filtration system, which has an innovative filter head design resulting in a ‘cyclone effect’ which diverts the inlet flow in a specific direction which enhances the flow properties and dirt absorption capacity. In addition, the filter also boasts a newly designed bowl which improves element mounting and stability which keeps the element in place ensuring constant pressure distribution. Chris Gray, Filtration Product Manager for Bosch Rexroth, commented: “The expansion of the Bosch Rexroth product portfolio into filtration enables our UK customers to access a complete hydraulic package from a single source. Filtration has been a clear gap in the Bosch Rexroth hydraulics portfolio which I am delighted to say has now been filled with the highest quality filtration products.”
Mogensen Sizers and detergent powder screening Earlier this year Mogensen supplied two 3metre wide Sizers together with matching vibratory spreader feeders to a major detergent manufacturer in India for the screening of detergent powders prior to packaging. This process is necessary to remove the agglomerates and flakes, which inevitably build up in the spray driers used to produce the powders - both for the sake of the appearance of the product and, more importantly, to ensure that the powders dissolve quickly and fully, and do not cause washing machine blockages. The history of Mogensen's involvement with detergent powder screening began in 1969 with prolonged, successful trials carried out using a half-metre wide Sizer at a major manufacturing site in the North-West of England. The trials were quickly followed by the installation of four halfmetre machines at the same works. Subsequently all of the company's detergent plants both in the UK and overseas were equipped with Mogensen Sizers. Other detergent powder manufacturers have followed suit and adopted the Sizer for this process application with the result that it is now standard equipment throughout much of the industrialised world. Each of the two Sizer / feeder units supplied to India can handle 35tph of powder, a very large volume in view of the extremely low bulk density of detergent powders, and scalp out anything coarser than 1.4mm. The feeders each accept a 1-metre wide supply of powder and spread it out evenly across the 3-metre Sizer width to ensure efficient and constant screening. Each of the four machines is powered by two 6-pole Invicta rotary electric vibrators; each rated at 6630 watts in the case of the Sizers and 2290 watts for the feeders. The necessary electrical control equipment, manufactured by Invicta, was also supplied. www.hub-4.com/directory/583
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Anaconda appoints second UK dealer! Anaconda Equipment, the Northern Ireland based manufacturer of mobile screening and stockpiling conveyors, have just announced the appointment of a second distributor for the UK market. Anaconda UK will join LH Quarry Group as the official distributors for Anaconda in England, Scotland and Wales. LH Quarry Group has long been associated with the quarrying and associated industries and has been providing Crusher Spares/Wears and a Machining and Fabrication facility for nearly 50 years. LH Group are located in Cleveland and will cover Scotland and the East of England. Anaconda UK is a new company set up in Cheltenham by Danny Morgan who has spent more than 20 years in the industry selling crusher and screens throughout the UK. Anaconda UK will cover Wales and the West of England
The equipment is extremely robust, well priced and performs extremely well in a wide range of applications. The SR514 triple deck screen is the latest screen to be added to the range and will offer four-way separation of material.
Anaconda's range of equipment includes conventional screening units, scalpers, trommel screen and mobile conveyors.
For more information on the range on offer please contact your UK distributor - see map for details. www.hub-4.com/directory/12687
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Recycling
Terex Finlay launches the new 883 Spaleck 3D Combi Flip-Flow Screen. Recently the HUB Magazine had the pleasure of attending the launch of the new Terex Finlay 883 Spaleck over in Belgium where beautiful weather and a real working environment for the 883 Spaleck allowed us to appreciate the capability of this new addition to the Terex Finlay range. The new Terex Finlay 883 Spaleck is claimed to be the ultimate in mobile screening and separation technology and is the result of a joint partnership between Terex Finlay, pioneers in mobile tracked processing equipment and Spaleck, the market leaders in static recycling screening technology.
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At the heart of the mobile plant is the 2 deck, German designed and constructed high performance screen box. This unique stepped top deck design combined with 'state-of-the-art' flip flow technology on the bottom deck catapults the Finlay 883 Spaleck into a class of its own. Its processing capabilities and application flexibility make the machine the only 'all in one' mobile solution for processing difficult waste, recycling, slag, C&D, shredded metal, wood, compost, mulch, ores, coal and soil. A unique 3D top deck design provides maximum screening efficiency whilst increasing overall productivity due to its anti-blockage design. The highly aggressive flip-flow bottom deck allows the machine to function in previously un-processable material whilst maintaining a high degree of screening accuracy. The first customer in Belgium has found that they had been cleaning their normal screen three or four times a day, and with the Spaleck they found it was always clean, keeping their downtime to an absolute minimum. The 883 Spaleck was really put through its paces. In front of a European wide crowd the 883 Spaleck was really put through its paces, and afterwards we conducted an interview to find out the important answers to a wide variety of questions from our readership. We spoke at length with Steven Aiken of Terex Finlay, who commented; “The mats have zero bolts, and are secured with a nylon strip allowing them to be pulled out quickly, cleaned and replaced. Two men can easily carry out a complete bottom deck change in less than one hour. The bottom deck has never blocked in situations ranging from slag, difficult steel, wet clay, and wet soil.�
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Recycling “The top deck 3D principle means that no hooked pieces of steel get stuck, so doesn't snag any other material such as plastics and timber, and the tapered angle means that spikes and long pieces of timber and steel can't get through.” “In terms of throughput, the 883 Spaleck can handle a max capacity of one hundred cubic meters per hour realistically. It can be slowed down to get a clean product on the blowing system, or ramped up to suit each application. Turners on the end of the decks topple material so that any larger items fall over and the dust and fines get through to the bottom deck.”
“Also upgrading existing Terex Finlay 883's is easy, with the retro fit option. It's possible to fit a complete Spaleck screen within 1-2 hours to an existing 883 machine on-site. The upgrade comes with box (top deck and bottom deck), drive system, hydraulic motor, mats, couplings, and springs.” All in all, we were very impressed with the Terex Finlay 883 Spaleck and it was obvious to see that the combination of the industry leading Finlay 883 heavy duty screener and the Spaleck 3D combi flip-flow make this a unique and versatile machine for the recycling industry.
“Changing the top deck is easy as each step is made up of 4 individual panels (all bolts secured from the top), with each panel weighing 40-50kg's which can be lifted by one or two people.” Steven Aiken further commented; “You can also mix and match with different size panels on the top and bottom to really help spread the materials. The screening mats are very high end high specification and Spaleck have spent many hours testing them to make sure that they stand up to the job.”
Key Features: • Virtually blockage-free screening in the upper and lower deck thanks to tried and tested 3D and Flip-Flow technology. • The 3D screening segments guarantee accurate screening with no long pieces passing into the middle-grade material. • The Flip-Flow screen with screw-less mounted screen mats avoids unnecessary cleaning and reduces maintenance times. • Screen-box discharge end can be hydraulically raised 500mm to facilitate efficient and easy media access and changing. For more information please visit www.terexfinlay.com If you would like to listen to the interviews and watch the video, please visit the HUB-4.COM website at www.hub-4.com/news/s3/6155/883 www.hub-4.com/directory/305
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Recycling
“Going for Gold” with new Commonwealth Games Construction and Demolition Aggregates Recycling Plant Terex Washing Systems (TWS) have just completed commissioning a 150TPH Recycling Wash Plant in Glasgow in association with their Scottish dealer Blue Machinery (Scotland) Ltd. The plant which is now up and running, 10 Hours + per day, was installed for the well know independent quarrying company Paterson's Quarries Ltd. The new site is located at their Greenoakhill Quarry & Recycling Centre, Glasgow. Austin Carey, Managing Director, Blue Machinery (Scotland ) Ltd commented “We are delighted to continue our close working relationship with Paterson's of Greenoakhill in supplying this new TWS washing plant for their new materials recovery centre at Greenoakhill . We have worked closely with the Paterson's Group over the last 10 years and look forward to a continued working relationship with them.” A bespoke Terex Washing System plant is processing construction, demolition and excavation waste to produce four grades of stone and two grades of sand. Fergal McPhillips, Sales Manager for TWS explains “Upon careful analysis of the feed material and being mindful of the large variation in the silt content, it was established that specific attention was necessary when choosing the sand plant. With this in mind a flexible sand plant with a unique pre-wash option was sure to be the perfect solution. Based on these findings TWS proposed a bespoke system which is now ensuring that the construction and demolition waste material is being effectively processed and is producing saleable aggregates and sand.” Garry Stewart, Applications & Sales Support Engineer, TWS added “The high silt content of Paterson's construction and demolition material was a challenge which TWS relished. We knew we had the expertise and technology to convert this sticky clay bound material into saleable building materials. The Paterson's material is hugely variable and it was critical that we designed and manufactured a plant which could handle these variations. On a recent site visit we witnessed at first hand the quality of clean aggregate and sand being produced.” Paterson's approached Blue Machinery (Scotland) Ltd as they required a Recycling Wash Plant to deal with tens of thousands of tons of construction, demolition and excavation waste. Extensive testing and sieve analysis highlighted that the material to be processed had a very high silt content of 30% plus. After consultation with Blue Machinery (Scotland) Ltd and Paterson's and vigorous analysis on the
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feed product, Terex Washing Systems proposed their range of cyclone separators and utilized a prewash to manage this high level of silt (less than 63 micron material). Sean Loughran, Director of TWS commented “Blue Machinery (Scotland) Ltd have a strong history in washplant sales in Scotland with the previous Powerscreen Brand and were the natural choice as the dealer for TWS in this area. The Blue Machinery (Scotland) Ltd sales team is highly respected within the Scottish market not only for high quality products they sell but also for their high levels of application and technical knowledge. The Paterson's Plant is a demonstration of what can achieved from initial conception through to the production of high quality products. Both Blue Machinery (Scotland) Ltd and TWS carefully considered the customer's specific needs and manufactured a truly efficient plant which is now producing the goods in terms of high quality recycled aggregates.” The end products are being sold into the market for construction projects and groundwork contracts throughout Glasgow as well as being used in Paterson's Readymix and their concrete block making operations. This Terex Washing Systems plant completes the recycling process with construction, demolition and excavated material taken from sites around Glasgow, which is processed and is then returned to those sites in the form of clean, sized aggregate for drainage, Readymix Concrete, concrete blocks and asphalt Commenting on the new wash plant, Director Tom Patersons added, “As a major supplier of construction materials into the central belt the new Aggregates Recycling Plant is an important investment for our company to ensure we are able to offer a sustainable source of high quality coarse and fine aggregate. Our location is ideally suited to minimise haulage to and from the market we serve, whether this is for the excavations coming off site or for supply of material back to site. The aggregates plant gives our site a new lease of life and will ensure a long term supply of high quality material for our customers and for our own complementary business of Readymix Concrete and Concrete Blocks” This is one of many plants TWS have installed where they continue to provide a unique solution for the customer's individual needs, which is achieved through years of expertise from rich heritage and legacy companies. Post plant installation, TWS is committed to providing outstanding customer support which is realized through their global dealer network, in this instance Blue Machinery (Scotland) Ltd. www.hub-4.com/directory/15386
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Mentor Training
Safe operation of fork lifts within waste and recycling facilities The changes in waste management operations in the UK have resulted in an increase in the number of Materials Recycling Facilities. These facilities are home to fast paced operations utilising large items of mobile plant equipment and fork lift trucks. Team these with limited space, pedestrians, conveyors, dust and noise and the accident potential increases. Between 2004 and 2011 there were over 200 reported incidents in the water supply; sewerage; waste management and remediation industries involving fork lift trucks. Mentor Training is asked more and more to deliver training to those operating materials handling equipment within the waste recycling industry, in particular MRF's.
Steve Baldwin, Mentor's Technical Manager, explains “Fork lift operation in a Materials Recycling Facility poses a whole set of different operational and observational issues from those experienced by someone operating the machine in the conventional warehouse environment. It is important that operators are trained to use their equipment appropriately for the tasks at hand and the environment in which they work and are aware of the particular hazards that the environment imposes�. Mentor provide 10 safety reminders for the safe use of fork lift trucks to those operating, supervising and working within a MRF. 1. Ensure that there is clear segregation between pedestrians and forklifts Pedestrian walkways and restricted areas should be established. More importantly, employees must be made familiar with the particular areas in which they are permitted to operate to ensure these are adhered to. All employees on site should be briefed on the dangers of working in close proximity to fork lift trucks. 2. Be observant of other plant (fixed and mobile) operating within the working area MRFs often have multiple equipment types operating in different ways in the same space. To limit the chance of incidents, ensure appropriate visual aids/cameras are present and in good working order, and that all staff are trained to use the correct observational techniques. 3. Be careful when handling non banded products Non-banded products such as tyres may present a hazard due to their varying condition and size. Their load centres have the potential to shift if they move during transportation; to limit the risk, make sure the load is secure before moving off and drive at a speed appropriate to the ground conditions and the load. Never carry a load that obscures your vision.
4. Handle un-palletised products with caution Un-palletised products, such as drums and baled waste, could also present risks with regards to condition, size and load centre. Drummed waste should be handled with care to avoid punctures. When dealing with baled waste, operators should be aware of the material contained within the bales to aid them in estimating load weights etc. 5. Careful stacking Non-banded and un-palletised products should not be stacked too high as their uneven weight distribution can cause them to become unbalanced far easier than palletised loads. 6. Use suitable attachments Many sites have fork lifts which carry out a multitude of operations using various attachments. Always use the correct attachment for the task required e.g. rotating forks for tipping bins, bale clamps when handling baled products, and standard forks for palletised loads. 7. Take extra care when operating indoors with little natural light MRFs are often large structures with little natural light available. If switching between operating indoors and outdoors, be aware that your eyes may take time to adjust. 80% of FLT accidents occur due to visibility issues; take extra care. 8. Account for the ground conditions Always adopt a safe travel position, accounting for the terrain; this should ensure that your forks avoid scraping the floor. If the ground is wet/greasy, don't over-rev the engine as this may cause wheel spin. You should always endeavour to move any dangerous debris out of the way of moving vehicles, but in this type of environment it is often impossible to remove all waste from the floor. Take care, driving slowly and carefully over it as you would over any uneven surface. Pre and post-operational checks are vital to ensure no plastic strapping/waste is trapped around wheels etc. Report any problems to your supervisor. 9. Adhere to speed/directional restrictions on site Most sites that use fork lifts have speed restrictions in place. It is especially important that these are adhered to on busy waste sites due to the high risk nature of the environment. Many MRFs operate a one-way system to facilitate the flow of traffic on site; ensure you follow this to limit the risk of collisions between the various vehicles operating simultaneously in the MRF. 10. Follow the correct procedure for loading vehicles Ensure that operators are familiar with the safe methods of loading/unloading vehicles (curtainsided lorries, for example) including operating on access ramps, if required. To download a free copy of the ten reminders for fork lift safety in MRFs please visit ''Safety downloads and posters'' under the Useful Information section of the Mentor website. For any further guidance on the safe operation of fork lifts on waste sites or at recycling facilities, please call Mentor on 01246 555222.
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Recycling
Two new innovations from MB The two smallest buckets of the range have arrived, the MB-S10 Screening Bucket and the MB-C50 Crusher Bucket Worsley Plant, supplier of materials processing equipment to the construction, demolition, waste management and recycling industries, is officially launching two new innovations from MB to the UK market at PLANTWORX 2013 in May. MB, the world leader in the production and sale of jaw-action bucket crushers and screeners, has developed two small treasures that complete the wide range of MB products: the new model MB-S10 Screening Bucket and the brand new MBC50 Crusher Bucket. Small, compact and light the two MB buckets are suitable for midi diggers from 4 to 8 tonnes and are ideal for use on small sites.
materials and the same technology as the already well-known MB Screening Buckets, the MB-S10 is easy to transport, manoeuvrable, highly competitive and is ideal for small sites and gardening work. The latest addition, the MB-C50 is the smallest in the Crusher Bucket range. Small and light (to make installation and use easier), the new MBC50 cuts down on processing costs and time and eliminates needless transportation costs. One-of-a-kind and certified, like the entire MB range, it is the only holder of the double jaw movement patent, to ensure the highest productivity on all sites. The new Crusher Bucket weighs 750 kg and has a loading capacity of 0.25 m3. Both new products demonstrate the continuous commitment of MB to be innovative, creating more and more cutting-edge work tools which are adaptable for a wide range of uses; a feature all of its products.
The new MB-S10 Screening Bucket weighs 445 kg and has a capacity of 0.6 m3, offering advantages that only MB products are capable of providing: high quality, reduced management costs and time saving. Developed using the same
MB continues to invest in research and development, focusing on the specialisation of top-performing and high-quality unique products that give the customer added value, real cost savings and efficiency. The two new buckets will be officially unveiled by MB at Bauma 2013 (15-21 April in Munich). www.hub-4.com/directory/7833
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Recycling
Barton Plant buys first Bell loader Barton Plant, part of The Bennie Group, has taken delivery of its first wheeled loader from Bell Equipment following a successful on-site demo. The move marks a shift from Barton Plant's usual preferred supplier, thus representing a further industry endorsement for the highspec Bell loaders, which have been available in the UK for only four years. Northamptonshire-based Barton Plant, which has an excellent reputation in the earthmoving, restoration, ground engineering and waste handling sectors, purchased its new Bell L1806E wheeled loader primarily to operate in its recycling and landfill operations. It followed a demo of a larger machine, the Bell L2106E, at the group's aggregates company Peter Bennie on site at Cauldon Low quarry. The loader will work in many different areas of the business as its size makes it very versatile and flexible. Pete Tye, service manager for Barton Plant, said the group in the past purchased loaders from another manufacturer but he was impressed by the high specification of the Bell machines, its price, availability and the service he has received throughout from Bell.
“We spoke to various people who run Bells as well as machines from other manufacturers, and I got a very positive reaction about Bell, so we decided to give them a go,” he said.
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“Looking at everything from the product to the after-sales, I have to say the results have been very positive. I was expecting a good quality product, and I believe that is what we got.” Tye, who has also purchased four B30D articulated dump trucks from Bell during the past two years, said the attitude of the Bell employees was a significant factor in his decision on the new loader.
“It's not about companies doing business with companies, it's people doing business with people,” he said. “If you take a dislike to a salesman, you are very unlikely to buy from him, and if you get a negative experience from the service department, you are not going to continue buying. “We were moving into new territory with the Bell loaders, so it was a risk, but I've so far been very happy with Bell. I have a great rapport with the people there, which is hugely important.” Nick Learoyd, sales and marketing manager for Bell, said: “We've worked hard to convince Barton Plant that our loaders can compete with the best of them out there.
“We're delighted that Pete gave us the opportunity to prove that to him with the on-site demo and obviously that it converted into a sale. “Bell has established a solid reputation for its all-round service over many years, but word also seems to be spreading throughout the industry that our loaders give great value for money as well as them having the highest specification on the market.” www.hub-4.com/directory/107
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Recycling
Ajax Equipment Screw Elevator and Hopper for Meltog Waste Processing Systems Solids equipment handling systems specialist, Ajax Equipment, has been awarded a contract to supply leading waste processing systems company Meltog with a heated screw elevator and hopper for handling shredded containers. This latest Meltog order follows the earlier supply of twenty compactor screws for a range of waste handling processes. The heated screw elevator forms an integral part of Meltog's fatty oils and packaging separation system by providing a means of secondary non-mechanical residue separation. This high efficiency secondary system applies heat to the shredded materials and oily residue through a fabricated steel steam jacket, which advantageously radiates heat whilst retaining the steam minimising heat losses and boiler load. The oils and fats are then collected separately for disposal whilst the shredded containers are elevated for further processing. The twenty carbon steel, compactor screws with 15mm thick flights were manufactured in house by Ajax to Meltog's specifications. The compactor screws feature both variable pitch and taper diameter geometry with hard weld configuration to enhance life and reduce normal wear characteristics associated with this class of equipment.
Meltog is using an Ajax screw elevator and hopper for waste processing.
“Ajax was able to advise on the best methods of fabricating the compactor screws. In particular the quality of their welding is well proven in-service, ensuring they are able to withstand the rigours of processing waste materials,� said Julian Heyworth, managing director, Meltog. For more information on Ajax Equipment screw feeders and conveyors, call +44(0)1204 386723, email: sales@ajax.co.uk and visit www.ajax.co.uk. www.hub-4.com/directory/43
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Recycling
CCC Waste Takes Terex Finlay 694+ To Improve Fuel Efficiency A machine provided by Finlay Central is helping a North West company save on fuel costs. The Terex Final 694+ Supertrak has been delivered to CCC Waste's Kirkby site - one of four depots it has across Merseyside and surrounding areas - and thanks to the machines versatility and dual capabilities, is helping the company save up to 20 per cent more on fuel expenditure. Producing up to four products in one pass, the machine has a new triple deck screen configuration with three full sized 20' x 5' belts as well as an innovative hydraulically controlled fourth conveyor. This allows for simple adjustment with variable tilt for stock piling of finished material. Incorporating a Cat 4.4 97kW (130hp) diesel engine, the Terex Finlay 694+ has first class production levels, quick set up time and a user friendly operation. Fed 100mm crush material, the 694+ produces piles of 100-40mm, 20mm, 10mm and fines. This is then distributed to CCC Waste's construction industry customers across the country.
As well as this, the machine is also working in tandem with a previously bought Terex Finlay J-1175+ Jaw crusher, to crush waste material before it can be fed through the triple deck screen. The 694+ then produces clean material at minus 4,10mm and 20mm. This is then stockpiled and sold for pipe bedding. This is the second 694+ machine CCC Waste has purchased from Finlay Central. CCC waste was established in 1986 by Ian Munroe, who started the business with one tipping truck. The company is now run by Ian's sun, Sean. Sean Munroe said: “We trialled other machines before we decided on the Terex 694+ but none of them achieved the same results. The main reason we wanted the plant was to make as many products in one pass as possible, something this machine does very well.” When not using the machine themselves, CCC Waste also hire out the machine to different wood screening and glass recycling companies. Sean said: “With the machine being so versatile and having such a large screening area the Terex Finlay 694+ can also be used to achieve a high production on screening wood for the biomass industry - as well as being used by glass recycling companies too.
“The machine is capable of handling large remediation projects, it covers the whole spectrum.” Neil Partington, Sales Engineer for Finlay Central, part of the Finlay Group of companies, added: “CCC Waste has been a customer with Finlay Central for more than 15 years and we have a good strong relationship with them.
“The 694+ is the second of its kind the company has purchased from Finlay and we are really pleased the company has decided to expand the already ten machine strong fleet with us.” A video of the work the 694+ is doing at CCC Waste is available to view here http://www.youtube.com/watch?v=NlWr9Z2otGY&feature= youtu.be
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Recycling
From crushing waste glass to cosmetics the swing hammer can do it all! The Glen Creston Swing Hammer mill range is designed for light/medium duty crushing of a broad range of materials in batch, in-line and recycling applications. Available in cast iron/carbon, steel and stainless steel with a blower discharge option, this versatile mill is a cost effective solution for process engineers. From waste glass to cosmetic pigments the swing hammer mill range will tackle many dry materials at rates of a few kilos to up to 1000 kg per hour, depending on material and screen size. The mill features a 180째 full width, discharge screen which is easily interchangeable once the safety interlocked top half of the mill is hinged back to give unrestricted access to the crushing chamber. Material enters the grinding chamber where it is ground by the action of swinging hardened steel hammers against a serrated face. The ground material then passes out of the mill through a screen. Normal discharge is by gravity but there is also a blower discharge option designed to help discharge of light materials that may otherwise remain in the crushing chamber. The durable mill body is constructed from cast iron with 12, 18 or 30 hardened steel hammers, depending on model. The hammers have four grinding edges which can be rotated in turn to give maximum life. The body, hammers and screen of the gravity discharge model can also be constructed of stainless steel for applications such as food or pharmaceuticals where corrosion resistance is essential. The mill can be supplied with a stainless steel hopper and a stand for use as a stand alone laboratory or batch grinder, or with just the motor bedplate for inclusion into a process line. This type of mill has been used successfully to grind Chemicals, Resins, Grain, Clay, Seaweed (dried), Fruit (dried), Wheat, Barley/Oats, Domestic waste, and Glass, but could be applied in any similar situation. The Swing Hammer Mill is only one machine from our range of laboratory and pilot scale/light industrial equipment. For preparation of larger laboratory samples or for light industrial applications, Glen Creston offers a range of machines that can cope with higher through outs whilst still producing reasonable particle sizes. From our Jaw crusher, for primary sample breakage prior to further processing, to the McCrone Mill, which will grind to analytical fineness, these machines can cope with a wide range of materials from rocks to edible grains.
Glen Creston also manufactures special machines for sample processing production needs. These mills are designed for processing small samples to larger scale machines for industrial applications. For further information about Glen Creston products please contact: enquiries@glencreston.com +44 (0) 208 545 9140 WWW.GLENCRESTON.COM www.hub-4.com/directory/9239
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Waste Sorting feature
Eriez PokerSort Recovers Troublesome Rod Shaped Metals Eriez Magnetics Europe Ltd, as part of its dedication to continually advancing and transforming the metals recycling industry, introduces the PokerSort into the European recycling market. This new Magnetic Separator uses a special design permanent Magnetic Drum to help alleviate issues caused by long rod-like pieces of ferrous metals, typically over 600mm (24 inches) in length, that can damage downstream equipment in automobile and other scrap metal operations. As the metal rods (e.g. automotive leaf springs, tie rods, steering and axle components) exit a shredder, alignment guides on the incline conveyor position rod-type objects parallel in the flow. As the rods reach the end of the conveyor, they extend beyond the conveyor and are magnetically pulled over the PokerSort, into a chute and collect in a bin or bunker. Carlton Hicks, Sales Manager - Recycling, commented, “Metal rods cause a big problem in scrap yards, they often poke through conveyor
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belts, causing jams and bridging conditions that can shut down an entire facility. Even a few minutes of downtime can cost thousands of pounds/euros in saleable product. By listening to our customers and studying the situation we [Eriez] were able to come up with a solution to this age-old and extremely common problem in the recycling industry.” In 2011, Eriez installed a PokerSort test unit at Liberty Iron & Metal LLC based in Eriez, Pennsylvania, USA and on site testing proved the PokerSort's remarkable performance, with 90% of rod shaped pieces of ferrous metal being eliminated. Since this time Eriez have now sold many units in the USA and have recently introduced the innovative Magnetic Separator into the European Recycling Market, with the first unit being sold to a large German waste management company towards the end of 2012.
“The PokerSort is just one more example of customer need driving Eriez innovation,” says Tim Shuttleworth, Eriez President and CEO. “With Eriez' 70 years in business, one of our main objectives has been to design equipment to help customers solve their toughest challenges.” He adds, “We are committed to on-going investment in R&D so that we can continue to introduce cutting-edge products, such as PokerSort, that enable our customers to become more efficient and profitable.” To learn more about Eriez' extensive line of products for the recycling industry visit http://engb.eriez.com/Markets/Index/Recycling or alternatively email info@eriezeurope.co.uk. www.hub-4.com/directory/280
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Waste Sorting feature
Overbands Reduce Shredder Downtime and Repairs
Recovering Ferrous Metals from waste product streams has become more and more profitable over the last few years with the significant increase in the value of steel. Many of the UKs recycling centres have also been upgrading their metal separation equipment because of the potential savings that can be made from avoiding unnecessary landfill and protecting any downstream processing equipment from large damaging metals. Last year, Master Magnets were contacted by a large recycling company based in Lancashire that was having problems with large ferrous metals making their way into their residual shredders. This problem had become more apparent after a flywheel had caused the shredder to break down, costing the company tens of thousands in repair costs. The company had two recycling sites in Lancashire and they were looking to install some very large Electromagnetic Overbands Separators at both locations. The magnets would need to be capable of extracting large ferrous objects from their product stream, before they reached the shredders. In order to help determine the customer's exact requirements, Engineers from Master Magnets accompanied the customer to the midlands based recycling site SB Waste, which already had a range of Mastermag Overbands in operation. After seeing an Electro Overband Magnet working on site and witnessing its extraction capabilities, the company were confident that Master Magnets were the right suppliers for the job and instructed them to design and manufacture their two units. Both machines are now installed at the Lancashire sites and are working very well at removing any large contaminants that could cause any further damage and disruptions. www.hub-4.com/directory/541
Metal Detection? The best value insurance. Leading manufacturer of recycling extruders for the plastics industry, especially film producers, describes fitting metal detectors to its range of off-line extruders as “The best value insurance against the risk of input contamination damaging the extruder SST screw and other internal components.� The in-line extruders face a very small risk and do not normally need metal protectors. Plasmac has worked with S + S inspection for several years and advise every customer to have S+S DLS metal detectors fitted to its off-line recycling extruders. Plasmac's Mark Richardson explains that the cost of fitting metal detectors is relatively low compared with the cost of machine damage and production downtime that may be caused by even a small piece of metal. This advice is occasionally rejected where cost is a major factor but not fitting the metal detector voids much of the machine warranty. Plasmac use S+S metal detectors exclusively because they are simple to interface with the company's control systems and reliability and good service over the long term. www.hub-4.com/directory/6628
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Quarrying
Wordsworth Crushing Ltd adds more crushing and screening power to their fleet. Based in Barnsley, South Yorkshire, Wordsworth Crushing Ltd has recently invested in two McCloskey S-190 triple deck, mobile vibrating screener, one R105 tracked screener and two McCloskey J50 mobile jaw crushers from the UK distributor Aggregate, Processing and Recycling Ltd (APR) of Tamworth, Staffordshire. With more than 25 years' experience in the supply of specialist contract crushing and screening services Wordsworth Crushing has an enviable track record on UK major projects, having successfully completed contracts in quarrying, site remediation, slag processing, demolition, chemical works and recycling. With the company ethos of highly maintained equipment, operated by fully CITB qualified, experienced and reliable drivers the recent choice to purchase the McCloskey machines was based on machine reliability, flexibility and cost effectiveness, all backed by comprehensive support from Aggregate, Processing and Recycling Ltd. Oliver Wordsworth - Director, commented, “The investment in the new McCloskey machines adds more power to our fleet of equipment and will allow us to offer our customers a more cost effective solution to their demands, with savings in fuel and increased productivity. R190-3 high energy mobile vibrating screener Currently being operated at Scunthorpe Steel Works the McCloskey S190-3 and the J50 Jaw crusher provides a highly effective crushing and screening combination for the project. A highly effective screener with quality components throughout, the S190-3 has a focus on usability and offers a range of customer focused features as standard, whilst pushing the industry production performance standards by providing the most advanced 20' x 5' portable vibratory screening plant in production today. The S190's unique high energy screenbox design provides optimum screenbox dynamics to give output levels that place the S190 in a league of its own.
Features such as the adjustable screenbox angles allow adaptability to a wide range of materials including quarrying, crusher circuits, sand and gravel, coal screening, topsoil, and woodchip. Having the highest grade specifications and component parts, the S190 has the highest combined true screening area across three decks. This class leading screening area, along with it high energy screening action (combination of optimised screenbox weight, shaft speed, and screen amplitude dynamics) ensure that the McCloskey Tripledeck models are the superior choice in aggregate material screening. Uniquely produced with a cross conveyor, and a fully hydraulic folding fourth conveyor as standard, this reduces set up time, the need for lifting equipment, and prevents damage or bending when moving the machine, or when setting up with manual lifting gear. With quality components throughout, the McCloskey Triple decks offer a reliable solution to the demands of customers application needs. R105 tracked high energy screener Working alongside the triple deck, the R105 two deck, high energy screener fulfils its duties as the best option for operators who don't require the full capacity of the larger models. Built from high quality components the heavy duty R105 offers durability, reliability and proven performance. Driven by a 100HP engine the R105 offers the highest stockpile (3,600mm) and largest screening area (12 x 4.5) in its class. Meeting the European transport regulation width the R105 also represents the most cost effective productivity and quality on the market. J50 jaw crusher In contrast, the J50 Jaw Crusher powered by a 350 HP Tier 111 Cat C9 engine is a machine with a focus on quality, durability, and productivity. Driven by a CAT C9 engine, and a 50'' wide jaw (the widest jaw in its class), the user friendly control panel with excellent machine diagnostics, places the J50 places at the fore of portable crushing machinery. Equipped with class leading, material throughput and capacity, the largest stockpile height in its class and an extended side conveyor as standard, the new J50 crusher continues to push the boundaries of industry performance. A professional parts and service package With branded components throughout and a high efficiency diesel hydraulic system providing higher throughput and lower fuel consumption the new machines are backed by a professional parts and service package supplied by APR who has an accumulation of over thirty years of experience in the construction industry. This experience has been gained from design, manufacture, sales and servicing of all types of construction equipment, specializing in crushing and screening equipment. Employing all their own fully trained service staff within an 18,000 sq. ft. workshop facility complete with all the necessary equipment to service, or if necessary manufacture new parts at their Tamworth site, APR maintain full control of their staff and facilities allowing the company to operate at maximum efficiency, offering a total after sales service package. Oliver, further commented, “It made sense to go with an experienced distributor who has the ability to offer a comprehensive service provided by their fully trained staff and workshop facilities.” www.hub-4.com/directory/33
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Quarrying
Hamilton Aggregates show how vision and the right partners bring success Growing from a single 0.5 acre quarry to a three quarry operation in the period of seven years, Hamilton Aggregates shows how vision, expertise and the right support, as well as equipment, can make a family business in Arkansas a leading supplier of aggregates.
Hamilton Aggregates' beginning goes back to February 2006, when Edward and Genia Hamilton decided it was the right time to set up their own quarrying business. Edward's twelve years in the industry as quarry planner, where he had the task of designing the most efficient operation processes, provided him with the expertise and the vision to see that given the right economic opportunities, the Hamilton's could run a very profitable venture.
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The Bonds quarry, located in Clinton, Arkansas, had an initial plant consisting of an Extec (now Sandvik) C12+ mobile jaw crushers and an E7 mobile scalper, which were rented from Brian Costello from Crushing Tigers; the local distributor of Sandvik mobile crushers and screeners. Showing an understanding of business strategy that would shame many large corporations, Edward developed a 20 year plan from the very outset, which included the acquisition of more equipment to supply a varying and growing demand. As mobile units can be moved to the source of material, and be quickly set up to process it on site, Edward decided to utilize their capabilities in order to make his operation more productive. The advantage of plant mobility alone would allow the quarry operation to save the time and money of having an operator transport the blasted material to a stationary crusher. Furthermore, the different models in the mobile range could be put to work in different combinations in order to suit differing customers' material requirements. This mobility and flexibility suited Edward's lean processing approach and with the guidance of Brian, Edward decided to purchase his first complete set of mobiles. The full initial set up, consisting of an Extec (now Sandvik) C12+ jaw crusher, an E7 scalper, an S5 doublescreen and an X44 cone crusher, allowed the site to produce 360,000 tons in 2007. During 2008 an extra jaw and scalper were added to the operation, which expanded an extra 5 acres, and produced 400,000 tons. In 2009, a challenging one for aggregate producers throughout the USA, saw the production decline to 300,000. However, Edward and Genia's focus on efficient production processes resulted in commercial prospects positive enough to open up an extra 10 acres in the quarry. Nowadays, the set-up consists of a Sandvik mobile QJ341 jaw crusher, a QE440 scalper, a QA450 triple deck screener and an Extec X44 cone. The Sandvik machines are the main material processing plant at Bonds, of which Brian Costello says, “There is a misconception that you cannot use the mobiles as the main equipment in a quarry. These machines can be very productive and are very cost effective”. The user friendliness of the machines contributes to their lower operating costs, as both crushers and screeners are designed for ease of operation; thereby one operator can run the whole train. As Edward Hamilton himself states: “These mobiles are quality machines. They provide us with lower operating costs and high production for their size”. Illustrating Edwards comments a variety of final material sizes are produced at Bonds; these include: • 1'': used in concrete rock • 1/2'': asphalt chip • 3/16'': asphalt dust • 11/2'' : road base • 4 -12'': erosion control.
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Quarrying The Greers Ferry quarry, located in Higden, AR, is another sample of how the combination of expertise and knowledge of the customer's needs allowed the Hamilton's to successfully grow their business. This site was acquired in order to supply material for the construction of a bridge for the Highway Department of Arkansas. The supply of high quality and competitively priced aggregates were crucial in securing the winning bid. In addition to the low costs of material transportation, due to the proximity of the quarry to the construction site, Edward knew that in order to provide the required high quality material at competitive prices, the output had to be planned from the blasting stages. Even though this planning can come at a higher price, since tighter patterns can be costly, they can also eventually save money on secondary crushing. As Edward explains, “For every nickel I spend (blasting), I save a dime in the crushing”. Hence a Sandvik QJ340 jaw crusher (predecessor to the current QJ341) is run in tandem with a QE340 scalper, crushing and screening limestone at 24'', which is then used for the foundation of the bridge, in addition to base, gabion and rip rap. The constant steady supply required from the Greer Ferry quarry emphasizes the need for a reliable aftermarket support; as Genia Hamilton explains: “Providing a good customer support has made us competitive in this market, so getting good customer service from Crushing Tigers has been essential. The fact that we can pick up the phone, and speak to somebody who knows about crushers, and our business, like Pat Doab, or Brian Costello, is a big thing.” As to the advice they have received Edward Hamilton adds, “The equipment has proved to be highly reliable, but after discussing our needs with Crushing Tigers we run the machines for 9 hours each day, and then run a preventative maintenance schedule to ensure reliability and maximum productivity”.
The full product offering which Sandvik has available, which caters for smaller producers as well as larger operations such as Hamilton Aggregates, has also been an added bonus from an after sales perspective. Edward explains: “The full range of Sandvik mobile crushers and screeners offered through Crushing Tigers proves very efficient for the running of our operation from the after sales point of view since we speak to the same set of people, who already know our needs, and our business”. Hamilton's Prior Mountain quarry located in Quitman supplies material on demand for the local market. This is easily accomplished as the mobile crushers and screeners may be easily and quickly moved between the different quarries, with production being rapidly started due to the machines very quick start-up. This flexibility allows Hamilton Aggregates to be highly responsive to different customers' needs. It is the versatility highlighted above, together with the Hamilton's' vision, which has permitted Hamilton Aggregates to diversify into contracting in 2009. This has been so successful that the current revenues for this activity amount to 20% of the annual turnover. Furthermore the prospects for added expansion of this side of the business are made favorable by the good resale value the machines get, and by the customer financing opportunities that Sandvik Finance, a company owned by the Swedish group, is able to offer. Over the last seven years Edward and Genia's vision has been proved correct, enabling Hamilton Aggregates to progress from a single 0.5 acre quarry, to now operating three separate highly productive, efficient, and profitable quarries, and supply a variety of aggregates for the construction industry's requirements. Hamilton Aggregates' operation has produced over two million tons of material, supplying a customer base that has grown to include gas industries, road asphalt companies, and even nearby counties. It has also successfully diversified into a growing contracting business. However, what has remained constant during this time has been that the expansion has been the result of intelligent planning, high levels of customer service received from the Crushing Tigers team, and working with quality equipment. These factors have all resulted in helping provide Hamilton Aggregates' customers with what they want, when they want it, and where they want it.
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Quarrying
Frimstone go for lease hire with option to purchase on Canning Conveyor SuperDrive™ Ground Conveyors. Bulk material handling specialist Canning Conveyor of Worksop, Nottinghamshire has recently supplied two conveyor systems to Frimstone Limited of Crimplesham, Norfolk. Frimstone Limited, a family owned business, has over 70 years' experience in mineral extraction, recycling and restoration projects. The company currently operates six sand and gravel sites, and one carrstone quarry where aggregates are supplied to trade and domestic customers throughout East Anglia. Following initial discussions with Canning Conveyor, Frimstone decided, rather than purchase the two systems outright they would take out a 5 year lease on the equipment. Colin Faiers - Finance Director, commented, “We looked at a variety of options to fund this investment and found that the lease hire proposal was the most attractive option. We particularly like the ability to spread the cost over five years as this allows us to match our costs to revenue and also match the cost to the projected life of the reserve.” The two conveyor systems which were manufactured at Canning's Worksop base, were delivered to site and fully installed on suitable civils (by Frimstone engineers) at Watlington Quarry within ten weeks of the order been placed. Increased efficiency and environmentally friendly. The new conveyors will enable Frimstone to increase production at the quarry which is near Kings Lynn in Norfolk. The conveyors will transport unprocessed material from the working area to a processing plant which is 1.3km away. Frimstone are looking to double production in the next twelve months and the conveyors offer increased
efficiencies over dump trucks. They are also more environmentally friendly minimising both noise and dust. The use of conveyors is also in line with the existing planning permission on the site and avoided the need for further planning costs. The two 600mm wide troughed belt conveyor systems are designed to accept up to 150tph of 50mm sand and gravel over generally level ground. At 420 and 150 metres in length they are both driven by a 37Kw and a 22Kw single drum ceramic lagged motorised Canning SuperDrive™ respectively. Supplied with high tensioned bend pulleys, jib discharge drums, loop bend drums, primary and secondary belt scrapers the installation includes discharge chutes with integral crash boxes and hinged inspection hatches. Both units are built on a substantial skid mounted frame with cantilevered jib discharge and are fully guarded. Including two complete conveyor systems, Canning also supplied loop take up units, heavy duty tail end loading sections, intermediate bays, blocked chute probes, rotation sensors and full length centrally mounted emergency stop pull wire systems. Geraint Morris, Interim Managing Director, commented, “The whole operation was supervised by our Site Manager, and from start to finish the installation went according to plan and was completed ahead of schedule. Overall a very successful project and we all thought the attitude and commitment of the Canning engineers was first class.” The benefits of a lease with an option to purchase. With over 90% of FTSE 100 Companies now using leasing, it is not surprising that over 30% of all capital equipment purchased in the UK is now leased. Leasing equipment is highly tax efficient and preserves working capital. Supplied at a fixed cost it provides an immediate payback, is easy to upgrade and on expiry of the lease offers Frimstone the option to purchase the equipment for a nominal fee. It's a very simple process that has allowed Frimstone to choose a fixed term between 1-5 years. All Frimstone then had to do was take out insurance cover, (including all third party liabilities) for the full market value of the equipment whilst on lease at Watlington Quarry. All maintenance and repair, or replacement of parts, are at extra cost during the lease period. www.hub-4.com/directory/1715
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Washing, Screening, Pumps Feature
Wopfinger Transportbeton invest in efficiency improvements at Eggendorf An investment in a new sand washing plant by Wopfinger Transportbeton Ges.m.b.H. at their Eggendorf site in Lower Austria has resulted in a 60% increase in gravel production (from 135 t/h to 220 t/h). Before the new Evowash sand washing plant was installed Wopfinger were working two shifts at Eggendorf to meet the capacity requirements of the ready mix concrete plant located at the sand and gravel pit. This has now been reduced to one shift as a result of both the quality and quantity of the washed gravel now being produced.
“Our previous sand production system was a real bottleneck for us and resulted in us having to work two shifts in order to ensure we had enough gravel to meet our concrete production requirements” explains Mr Franz Denk, Technical Director at Wopfinger Transportbeton Gges.m.b.H. “By addressing this issue we have introduced significant efficiencies into our production processes at Eggendorf.” The decision to invest in the new Evowash system was made following a visit to the Eggendorf site by CDE Sales Manager for Austria, Mr Stefan Hunger and CDE Sales Director, Enda Ivanoff. This was part of a programme introduced by CDE to work with existing customers on strategic cost saving initiatives. “We visited the Eggendorf site following an invitation from Mr Denk and conducted a full audit of their existing processing plant” explains Enda Ivanoff. “It was clear that by introducing the Evowash they would eliminate the loss of quality fine sand, which would make a significant contribution towards optimising performance.”
The new Evowash 101 sand washing plant produces 100 tons per hour of washed 0-4mm sand which is exclusively used in on-site concrete production. The Evowash receives material from the existing wet screening plant directly to the sump where it is then pumped to the integrated 625mm cyclone. The underflow from the hydrocyclone is discharged onto the Evowash dewatering screen and stockpiled while the waste water containing the 0-63 micron fraction overflows the top of the hydrocyclone and is sent to settling ponds. Wopfinger Transportbeton have manufactured concrete at Eggendorf since 1990 and the plant was upgraded in 2011 to support the construction of the A2 Motorway for which Wopfinger supplied more than 25,000m3 of concrete. The Eggendorf production facility is located just off the A2 approximately 50kms south of Vienna and is one of 4 gravel plants operated by Wopfinger Transportbeton in Lower Austria. In total the company has 14 concrete production facilities in East Austria. We have developed a reputation as technical leaders in the production of ready mix concrete in Austria. The production of a consistent washed sand product is crucial to maintaining quality and performance across the range of concrete products they manufacture and the introduction of the Evowash system has ensured delivery of a washed sand which meets these strict quality requirements. This project by Wopfinger Transportbeton is indicative of a renewed focus from the construction materials industry on the identification of areas for investment that will create efficiencies and reduce costs within existing processes. “The feedback we are getting from our customers indicates that there is an industry wide recognition that investment in new equipment as a means of reducing costs is not only viable but essential” says CDE Sales Director, Enda Ivanoff. “Our project at Eggendorf is a good example of the benefits to be gained from this approach.” www.hub-4.com/directory/163
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Washing, Screening, Pumps Feature
Flex-Mat® 3 Modular Locking System Options significantly increase open area without costly screen box modifications. Montreal-based Major Wire Industries Limited offers a wide variety of Flex-Mat® 3 Modular High-Performance, Self-Cleaning screen media panel locking systems that increase overall screening production without costly screen box modifications. These locking systems, including “Pin & Leg”, “Pin & Leg MAXI”, “Pin & Sleeve”, “Grooved”, “Step”, “Snap C”, “Snap P” and “Snap 2K”, fit virtually any existing screen box. Snap- and step-type panels are available in 1-foot x 2-foot (305-mm x 610mm) sizes, while the pin- and grooved-type panels are available in both 1-foot x 1-foot (305-mm x 305-mm) and 1-foot x 2-foot sizes. All locking systems fit competitive dimensions as well. They install easily using the same fastening systems as traditional polyurethane and rubber panels and are available in both stainless steel wire and Major Wire's proprietary OptimumWire®. Flex-Mat 3 Modular panels replace existing polyurethane and rubber panels wherever throughput is compromised, such as at the discharge ends when throughput is critical, or the entire deck for maximum production. Flex-Mat 3 Modular panels employ the same independently vibrating wire technology as Flex-Mat 3 Tensioned panels to better separate material, increasing throughput up to 40%, as well as virtually eliminating blinding, pegging or clogging. To date, Flex-Mat technology has been proven in more than 20,000 applications worldwide. Available in opening sizes ranging from 30 mesh, or 0.0197 inches (0.5 mm), up to 1.575 inches (40 mm), Flex-Mat 3 Modular 1-foot x 1-foot and 1-foot x 2-foot panels provide up to 50 percent more screen media open area than traditional rigid polyurethane and
rubber panels. Flex-Mat 3 Modular panels are available in the following configurations: a diamond-shaped Series D for most standard applications; wave-patterned Series S for removal of fines; and triangular Series T for fine screening. Flex-Mat 3 Modular panels allow precise passing for up to 50 percent of the wire's wear life, whereas a traditional polyurethane or rubber panel's 7degree demolding angle results in its openings widening as soon as the top surface is worn. Both Tensioned and Modular Flex-Mat 3 panels are an ideal screening solution in many applications, including aggregate (stone, sand and gravel), mining (successful in a variety of minerals, including coal, gold, magnesium, salt, etc.), aglime, C&D recycle, talc, asphalt and industrial minerals. www.hub-4.com/directory/7555
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Washing, Screening, Pumps Feature
New heavy-duty trommel from Ronald Gill Associates Developments in screening media from Tema Isenmann Now available, ISEREC flat-wire harp sieves are manufactured from upright, adjacently positioned flat wires that are held together by steel or polyurethane cross bindings to form a sturdy square mesh. The pitch of the cross bindings can be individually adjusted to suit the screening machine's support structure and the material to be screened.
Ronald Gill Associates have announced the addition of a new heavy duty trommel to their already extensive range of trommels. Bridging a gap in the market between smaller, lighter, lower cost skip waste machines and larger, more expensive, heavyweight scalping units, the new, all electric HD2400 sits in the mid-price range, aimed particularly at the quarrying and mining industries. Weighing 20 tonnes and designed to accept rocks measuring up to 300mm square, the HD2400 model measures 9010mm in length x 2730mm in width x 5500mm in height (variable). The machine is equipped with a 5060mm long x 2m diameter chain driven trommel drum with an effective screening length of 4500mm. The drum ends and three centre cylindrical rings are all manufactured from 20mm thick plate, together with five 80mm x 30mm back up flats rolled on edge, while four longitudinal split 'U' beam pieces form 'T' sections that are bolted and welded to the cylindrical. The 15mm thick (minimum) bolted/replaceable mesh plates are supplied in steel or Hardox type material.
When installed in a vibrating screening machine the upright wires of the ISEREC flat-wire harp oscillate as a result of the large span of the cross bindings. This achieves very effective screening, with minimal blinding and accurate separation. The robust construction offers a service life several times longer than traditional self-cleaning harps produced with round wire. ISEREC flat-wire harp is predominantly used in highly abrasive and heavily loaded applications where damp/moist materials that are difficult to screen, tend to blind and adhere with conventional wire meshes. Available in Spring Steel (DIN EN 10270-1) or Stainless Steel (1.4301) with a maximum wire screen width of 2500mm in various apertures ranging from 4.0mm to 39.0mm. Tema Isenmann are based in Woodford Halse, Northamptonshire and supply a full range of screen systems including woven wire, harp sieves, rubber and polyurethane in tensioned and modular formats. www.hub-4.com/directory/816
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The drum runs on six solid steel trunnion rollers (each roller has a 20-tonne dynamic load-bearing capacity) each mounted in grease-lubricated, lip sealed roller bearings. Each of the two axial drum locator rollers at the discharge end of the drum also has a 20-tonne dynamic load bearing capacity. A hinged spring loaded drive table allows constant tension and chain stabilization. The trommel drum is fed via a 5m3 capacity hopper and vibrating plate feeder equipped with Vibtec vibrators. Measuring 3950mm in length x 2100mm in width the hopper has 20mm thick side and end plates and is supplied complete with metallic dust and guard covers. A fines conveyor with base chute can be incorporated for dross or other types of cleaning or separation. www.hub-4.com/directory/732
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Washing, Screening, Pumps Feature
DSC Marlin Dredges Deeper The Marlin Class underwater pump mining dredge manufactured by DSC Dredge LLC is designed to meet the needs of deep mining and aggregate deposits by providing a more efficient tool for material excavation. Every Marlin Class dredge is specifically designed to handle a particular deposit-from sand and gravel to industrial minerals-to ensure maximum efficiency. Deep digging capability is made possible by the use of an underwater pump system with a high torque cutter drive assembly to complement the rigorous demands of the deep mining industry. Digging depths range from 35 feet (10 m) to more than 200 feet (61 m), an achievement unmatched in the dredging industry. Discharge sizes range from 8 inches (203 mm) to more than 24 inches (610 mm) to allow for a wide range of production and flow conditions to match specific mining operations. DSC Marlin Class dredges are available in either a diesel- or electric-powered model to meet the customer's specific needs. Drive systems include a Caterpillar ACERT diesel engine with inline direct marine style transmission for dredge pump reduction, or TEFC electric motor, variable frequency AC dredge pump motor drive and double helical gear reducer for dredge pump reduction. All models feature a PLC operating system, magnetic flow meter, electro-proportional hydraulic circuits, highcapacity service water system, maximizer suction dilution valves and a 3-wire mooring system. These performance features offer deep water dredging capabilities combined with a wide array of suction and discharge sizes to maximize operating efficiencies for every customer's operation. In addition to these premium features that maximize operational efficiency, every Marlin Class dredge is supported by the best manufacturer support package in the
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industry. DSC builds each unit to the exact requirements of a particular operation with quality in design. The company provides customers with intensive on-site operations and maintenance training upon system delivery and long-term aftermarket service and parts support throughout the world. Technical, engineering and parts support is available for all types of dredges across the world. DSC's in-house automation department designs custom packages that can be added to any dredge.
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Washing, Screening, Pumps Feature
Sykes Pumps launches new super silenced, medium head pump
Weir secures £4.4m pump supply deal for Kazakhstan's largest mine Weir Minerals has won a £4.4million process equipment supply order for the Bozshakol copper mine sulphide plant in northern Kazakhstan, which will access one of the world's largest undeveloped copper-ore deposits. The project is being developed by Kazakhmys PLC, a London-headquartered mining company, and is expected to output an average of 75,000 tonnes of copper concentrate per annum across its 40-year lifespan, with production scheduled to begin in 2015. The order will be delivered by Weir Minerals Europe, assisted by the Projects team of Weir Minerals Australia. As well as a wide range of process pumps and tailings pumps, the order includes Warman® 650 MCR® pump units - the largest mill-circuit pumps ever to be sold on the European market at 11.5ft in diameter - along with a complete replacement wet-end assembly. Bozshakol is Kazakhstan's biggest singlemine development both in value and volume terms, costing an estimated £1.3 billion and employing 1,500 people. Carola Schulz, Sales & Marketing Director at Weir Minerals Europe, said: “Bozshakol is a landmark project not only for Kazakhstan but globally, being one of the largest deposits of copper ore to have been left untapped.
“It is also a significant project for Weir Minerals, demonstrating our ability to deploy the specialist capabilities of our companies around the world to meet the needs of mining operations of any shape, size or location.” www.hub-4.com/directory/507
Continuing its investment in to the development of a range of super silenced pumps, Sykes Pumps, the pump hire specialist, has today launched its new MH150/100 Super Wispaset. This Medium Head pump is aimed at specialist markets such as mines & quarries; the marine industry; power generation; petro-chemicals, refineries and construction. Applications include pressure testing, batching plant washing, emergency or temporary fire mains and any situation where high vertical and/or long discharge runs are required.
Specifications The new MH150/100 Super Wispaset raises the bar in terms of low-noise pumping without compromising on power, reliability and flexibility. Employing a 129kW Iveco engine, the unit is capable of heads up to 105m, with a maximum flow rate of 320m3/hr (or 89 l/s) and noise levels down to an average of 70 dBA at 7m. The pump is set to run at 1800 rpm which means that fuel costs can be lower and engine noise reduced. In fact, when operating at Best Efficiency Point, the fuel consumption is an economical 21 l/hr. Despite being aimed at applications where there is a low concentration of solids, the unit has a credible solids handling capacity of 20mm spherical. Other key features: • Automatic control panel & optional Telemetry facilities - providing remote monitoring and management, which can highlight issues often before the user is aware. • A broad curve producing high flows at most heads. • Robust chassis for use in demanding environments and rugged terrains. • Super silenced canopy with access to all areas for ease of maintenance Chris Graham, Pump Development Director, Sykes Pumps said: “For a number of years now, we've made a very deliberate effort in bringing new pumps to the market that have a clear focus on sound attenuation, durability and fuel economy.
“It has been possible to develop this new Wispaset pump by understanding the very unique needs our clients have in extremely demanding industries and market sectors. Our new MH150/100 pumps ensure clients do not have to choose between productivity, efficiency and having an environmental conscience.” For more information visit www.andrews-sykes.com www.hub-4.com/directory/12633
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Washing, Screening, Pumps Feature
Analysis Equipment of Outstanding Quality Endecotts are proud to present their new sieve shaker 'the D300'. The D300 bridges the gap between the Octagon D200 and D450 and has been developed using the same advanced technology as the D450. It is extremely versatile accepting both 200mm and 300mm diameter sieves. Like the Octagon D200 and D450 this machine gives the operator total control of the sieving process. By utilising the same dynamic control panel as the D200, the D300 offers outstanding control features. The complete vibration system has been built to handle the sample weights involved with larger diameter sieves eliminating the problems involved with lighter weight machines. These features combine to give an extremely high performance shaker. Endecotts also offer a wide range of other sieve shakers suitable for all types of sieving and samples: M100 - The low cost M100 is an excellent small laboratory shaker designed for 100 mm and 3 inch diameter sieves. It is robust, lightweight and provides the user with complete control over amplitude and vibration time. Minor M200 - This shaker has been designed and manufactured to combine low cost with the benefits of a well designed and engineered shaker incorporating many features usually found only on larger more expensive models. The Minor M200 is easy to use, compact, and quiet in operation.
Octagon D200 - The Octagon D200 is ideal for laboratory or on site use. It is robust, compact and sufficiently lightweight to be portable. A digital display makes the setting functions very straightforward. D450 - The D450 shakers are fitted with a unique clamping system, which ensures that sieves are held firmly without over tightening and allows them to be quickly removed and replaced. The D450 is powered by an electromagnetic drive which has no rotating parts to wear making it virtually maintenance free and extremely quiet in operation. EFL - The EFL has been specially designed to operate with heavy samples without the loss of performance. It is equipped with a dynamic power source that ensures the right vibration is imparted to the sample for fast, accurate and reproducible tests. Endecotts Test Sieves Endecotts Test Sieves are designed and manufactured to offer qualities that make them extremely precise and accurate whilst offering good handling, nesting and strength. Each sieve is individually made under the most stringent quality control procedures using only the finest materials. The wirecloth is checked at every stage of manufacture either by optical projection or highly sophisticated computer scanning techniques. The final inspection is a precision measurement of apertures, and sieve frame dimensions. Only when we are satisfied it meets our exacting standards do we give it an Endecotts Certificate of Conformity. Endecotts Test Sieves are available in different sizes, depths, materials and certified degrees of inspection to meet every National and International standard and virtually every specification, including ISO 3310 and ASTM E-11. For further information on Endecotts products please contact: sales@endecotts.com +44 (0) 208 542 8121
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Bulk Materials Handling
Wear resistant linings improve productivity and reduce costs in dry bulk solids equipment
Cargo holds being lined with K-PLAS polymer wear resistant lining systems
Wear resistant lining specialists Kingfisher industrial explains how they have sustained their competitiveness within the dry bulk cargo handling market. By successfully carrying out projects within the UK and overseas they continue to be at the forefront providing turnkey packages for process plants and process equipment.
“Here at Kingfisher we carry out a number of activities that help us gain that competitive advantage within the market place,” stated MD John Connolly. ''By using our own skilled engineering project management and site based operatives we can undertake a vast majority of engineering, design, manufacture and online installation. With the integration of both manufacturing processes and operational activities we have made continuous investments in new design software & CNC manufacturing machinery, thus reducing the risk of non-conformance through protracted supply chain and eliminating the costs of 3rd party overheads and margins.'' The economic benefits of using wear resistant linings were proven recently at a major coal import facility within the UK that supplies various power stations with their bulk material. Kingfisher's Commercial & Exports Sales Manager commented “we were assigned the project to reline two ship unloaders on the plant, due to the high levels of abrasion and wear caused when handling coal” Kingfisher recommended lining both unloaders with a combination of our KPLAS polymer and K-CLAD metallic lining systems.
Many power stations are converting from coal to the use of biomass material. Due to the high abrasive nature of these materials, incorporating a wear resistant lining system within the plants process equipment is the ideal solution. Kingfisher have been working with a number of power plants converting from coal to biomass, to name a recent project that was carried out towards the end of 2012 the important part of this project was to design, manufacture and install spiral chutes to transfer wood pellets into the storage/feed bunkers. The design brief for Kingfisher Industrial was to provide a continuous, uninterrupted flow of wood pellet biomass without causing any material degradation to the process itself. The complete project was contracted to Kingfisher Industrial, whose experience in bulk material handling solutions enabled them to deliver the final solution, from design to installation within 5 months. Kingfisher's overseas presence has increased over the last couple of years; recently they were approached through an overseas agent to provide a solution for a coal terminal in the Asian pacific. The project involved the replacement of coal transfer chutes, the chute structure had been compromised due to the abrasive nature of the material conveyed, due to the existing chute design they were experiencing continual blockages when handling coal imported from Indonesia that has natural high moisture content. With no consistent material flow this caused misaligned material discharge effecting belt tracking and the life of the conveyor belt. The solutions offered by Kingfisher were to re-design the conveyor chutes. This process incorporated enhanced structural geometry providing a consistent flow of material through the chute preventing blockages and provided central discharge onto the receiving conveyor belt. By installing a combination of wear resistant and low friction lining materials this ensured service longevity & operational availability. Following installation and commissioning the benefits were immediately recognised. A reduction in demurrage costs, reduced maintenance costs and eliminated operational downtime as the requirement to unlock the chutes were significantly reduced.
A spiral chute for a power plant
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Referring back to dry bulk solids another popular mineral that is also considered highly abrasive is potash, a combination of various mined and manufactured salts that contain potassium. A project carried out in 2012 involved a large bulk cargo handler whom currently delivers 500,000T of potash by sea; the port also handles third party cargo including 250,000 tons of export grain and bulk minerals. Due to successful past projects carried out for the plant. Kingfisher were awarded the full turnkey project of re-design, manufacture and installation of another conveyor chute. Kingfisher are able to demonstrate the different types of lining solutions available throughout the process of handling coal within a bulk terminal. Starting when the coal arrives at port they have developed various lining solutions protecting and enhancing the performance of the reception hoppers, the conveyor system, stacker reclaimers through to the rail loading facility. Throughout the process, equipment is subjected to impact, friction and sliding induced abrasion. By installing a combination of K-ALOX, K-BAS, K-ZAS and K-CLAD materials this takes into account the differing levels of wear at various points in the transfer chutes. The linings are supplied in various thicknesses, offering guaranteed long term protection of up-to (10-12 yearsplus) against perforation of the fabrication providing the end user with a long term, cost effective solution they are encountering.
A spiral chute for a power plant, the design brief for Kingfisher were to provide an uninterrupted flow of wood pellets, without causing any material degradation to the process
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Wet Weather Provides No Barrier to Ground Stabilisation and Remediation with Allu System The Allu Stabilisation Bucket is proving its worth in the UK construction sector, enabling on-site remediation works to take place, despite the recent wet weather conditions. Available to UK contractors and plant hire companies from Finlay Hire, the Allu Stabilisation Bucket, commonly used by remediation contractors, has been put to work on sites that have become water-logged after months of rain. Such conditions impede plant movements and general site activity - but the arrival of the Allu Stabilisation Bucket allows the ground to be excavated, screened for oversize and dosed with lime for stabilisation to produce a backfill material. This process - involving just one Allu Stabilisation Bucket - has little impact on the day-to-day operations of the site and delivers a hard-standing surface as a platform for development projects to continue. The Allu Stabilisation Bucket is designed specifically to 'screen and stabilise' difficult materials such as clay and waste with high moisture levels, which is too cohesive for traditional screens. Chris Bell of Finlay Hire Ltd - part of the Finlay Group of Companies, said: “The Stabilisation model of Allu Bucket, with its ability to handle wet and cohesive material, is ideal for the conditioning of material that would otherwise have to leave site, with all the cost and disruption that entails.
“Without the ability to stabilise the ground and faced with consistent bad weather, contractors can face the prospect of removing unsuitable soil to landfill and replacing it with virgin aggregate to make the land good. “The Allu process reduces road usage and costs by negating the need to transport materials in and out of the site, which is an important consideration in built-up residential areas. “With any material, the processing will involve some manipulation with an excavator or wheel loader. When it is possible to move, screen, crush, aerate and mix with just one attachment, the benefits of the Allu system provide a compelling offer.” www.hub-4.com/directory/1824
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Replacement of Ribbon Mixers with Pan and Planetary Concrete Mixers Results in Improved Quality of Concrete SUBHEAD: General Shale, a concrete masonry products producer based in Tennessee, USA, recently decided to replace their ribbon mixer with a Rapid International RP2000 Planetary Mixer. Having been greatly impressed with the Planetary Mixer's fast mixing times and the quality of the concrete produced, General Shale subsequently replaced a second ribbon mixer with a Rapid Pan Mixer. General Shale approached Standley Batch Systems, a US Rapid International dealer with fifteen years experience installing Rapid Mixers throughout the United States. First and foremost, the company were concerned that their ribbon mixers produced concrete with too many unmixed particles and which did not meet with their quality standards. Standley Batch Systems were on hand to advise them on the best replacement options and guide them through the entire installation process.
Consistent Mix with Colour Blending Options The Company decided to replace one of their ribbon mixers with Rapid International's RP2000 Planetary Concrete Mixer - a powerful mixer which creates a more consistent mix and offers the ability to add several color blending options. Once the existing ribbon mixer was removed, it was important that the new equipment was integrated with General Shale's existing equipment; this involved installing new support beams and feed chutes. The installation was finalised when Standley Batch Systems wired the new control, which came with the new mixer, and piped in the new water line. General Shale also took the opportunity to add a new moisture sensor. This sensor controls the amount of moisture in each batch, which helps create a more homogeneous mix. From start to finish, the replacement process took about one week. The new Rapid Planetary Mixer now offers General Shale fast mixing times with increased concrete production and a consistent, top quality mix. Pan Mixer Installation in Lintel Plant General Shale were so impressed with the results of their new Rapid International Planetary Mixer; they contacted Standley Batch Systems to replace another unit in their Lintel plant. Although the new plant had a much different layout, Standley Batch was again able to take a concept drawing and custom fit the new two-door Rapid R500 Pan Mixer that supplies the Lintel machine. The team removed the Lintel machine to allow easier access to the Mixer, then cut the support platform loose from the old mixer and used the forklift to remove it from the building. The new Mixer platform was then installed one beam at a time. The Lintel machine feed chute was modified to accommodate the door from the Rapid Mixer. Load cells, two slide gates and two new feed chutes were added to the Mixer and a stainless steel hopper was also installed, as well as grating, handrails, toe plates and a set of stairs to the new Mixer platform. A local electric company wired the load cells, gates and mixer. General Shale installed all of the air and water pipes to the new mixer. www.hub-4.com/directory/5066
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Large interlocking concrete blocks as optimal solution for storage of bulk material
Following a fire in a storage building, logistics company M. Zietzschmann from Neuss in Germany had to search for a suitable solution for storing and handling bulk material with special requirements. The search led to the Dutch company, Jansen Betonwaren. The firm's 'Legioblocks®' proved themselves to be an economical and effective solution to meet the special requirements of the storage site. Jansen Betonwaren B.V. has developed a construction system using large-sized concrete blocks which can be easily stacked, virtually without any fixing material, thus offering outstanding flexibility. These concrete blocks, called Legioblocks®, can also be used to build long-lasting, robust and reliable constructions such as retaining walls, factory buildings or storage bins for bulk material. And this is exactly the kind of solution that Günter and Tobias Haberland, directors of the logistics company and cargo-handling terminal operator, M. Zietzschmann GmbH & Co. KG, and their architect, Mike Bollongino, were looking for. In 2011 a 50-year-old storage building belonging to the company burned down and it was necessary to rebuild. And in a storage facility consisting of a single continuous space, it is above all the storage of fertilizers and other aggressive materials (such as chemical precursors) that presents a problem, as the substances they contain are very corrosive to metal. For this reason, a solution was sought that did not involve vulnerable metals. A new storage facility with an indoor and an outdoor area naturally needed to be suitable for storing other types of bulk materials, preferably in a space-saving and economical way. “We wanted a solution that could be implemented quickly and efficiently, that offered a relatively high degree of variability, and that was also cost-effective,” explains T. Haberland.
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As the company had already had a smaller external storage area built with the help of Legioblocks®, the system was known and could now be applied on a large scale. Within a construction period of just six weeks, some 5,400 of the blocks weighing 2.4 tonnes each were put together. Because of the height of the walls, at 8.80 metres, as well as the 12-metre-high fire protection wall, foundations were needed. However, it was possible to use much shallower foundations than would be needed when using other construction systems. “In contrast to concrete walls, for example, with their deep foundations, Legioblocks® also have the advantage that they do not contain vulnerable steel elements, which would be corroded by fertilizers,” G. Haberland emphasises. “And for the foundation we decided on a 1.20-metre-deep strip foundation, so that we could erect a really solid building,” adds architect Bollongino, “this way we were in a position to build a tall storage space, which offered excellent conditions for bulk materials. It's possible to pile up material to a height of 6.10 metres. First, though, it was necessary to create a completely even base, so that the 160-cm-long Legioblocks® could be stacked without any problems.” The first construction layer consists of bevelled-edged base blocks, which ensure that loose material cannot get stuck in the corners of the building. The 11 layers of blocks can then be added. Haberland is especially proud of the buildings' optimal usability: “We would never have been able to achieve the fill height of 6.10 metres with any other method.” That really was Jansen Betonwaren's Unique Selling Point. Haberland explains: “The bins are filled from above by crane. For this we've incorporated three aluminium roof elements that slide over each other, as in river barges, so that the entire length of the storage area can be used and there isn't just one single heap of material. Alongside the use of this functional building material, this is the second innovation in this storage building, which reduces the amount of handling work involved.” The walls of the building with their imposing concrete blocks, rising nearly 10 metres into the air and crowned with a vault of larch wood, are almost reminiscent of the temple walls of the ancient Egyptians, which go back thousands of years and retain their strength and durability to this day. “I think it's classy!” declares Bollongino with pride. Legioblocks® are not only particularly durable - they can either be reused for building or crushed, classified and then used as raw material for new production. “This completes the raw material cycle,” adds Math Janssen of supplier Jansen Betonwaren B.V. The company can supply customers who have opted for this durable product with its many advantages through its branch office in Germany, the UK and a number of locations in the Netherlands. www.hub-4.com/directory/14510
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The clever option REMBE® LTD Incorporated in 2009 has been marketing the C-LEVER In-Line flow meter in the UK Bulk Solids industry with a wide range of success. Is this equipment really as good as it is claimed to be? Michael MacClancy M.D. of REMBE® LTD goes into some detail: In today's high-tech bulk solids and process industries, true product advancements in the instrumentation field are relatively rare and when launched are often greeted with a degree of scepticism and natural unwillingness by engineers to take that leap of faith and act as a 'guinea pig' and use NEW TECHNOLOGY. A user reference list is normally essential to provide the desired reassurances to justify making a considered engineering decision, resulting in the usual chicken-versus-egg dilemma…How do you get an installed reference list without cooperative 'guinea pigs'. With the innovative C-LEVER in-line flow meter REMBE® LTD, to some extent, have been facing similar market obstacles when discussing the impressive accuracy of this unit. For many years the more common impact weighing technology, wherein an impact plate deflects on a load cell
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to give an inferred weight and accuracy at best of 2 to 3%. This accuracy suffers further with changes in product characteristics, bulk density, temperature or pressure. The C-LEVER flow meter is a dynamic flow meter working on the principal of centripetal force, offering a step-change in measuring accuracy of 0.2% and a turn down ratio of 20:1. Product characteristic changes have negligible adverse effect on the repeatable accuracy. In operation the product is being measured throughout its flow through the C-LEVER So what is centripetal force? In simple terms the mathematical definition is: “A force which keeps a body moving with a uniform speed along a circular path and is directed along the radius towards the centre”.
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Weighing Systems Feature The mathematical formula being
f=m x v2 / r where f = force m= mass , v = velocity and r = radius of curvature.
The step-change in improved accuracy broadens the market potential for the C-LEVER where impact Weighers would not be considered. For example Lorry load-out or batch weighing, where accuracy is important and the only option is weigh feeders or static weighing which are expensive or cannot be used in continuous weighing. To date the C-LEVER is being used throughout the UK in a diverse range of applications, some of which are challenging with regards to product density and moisture content; however the C-LEVER is successfully meeting the application challenges head on. Some typical applications are pictured throughout this article To convince the market further, REMBE LTD have now commissioned 'Professor Michael Bradley' of the Wolfson Centre, the University of Greenwich, to conduct flow tests on three different bulk materials of varying densities: Barley Malt, Bread Flour, Animal feed pellets, in order to prove accuracy and repeatability of the C-LEVER InLine flow meter. The first material tests 'Barley Malt' are now complete. Below is in interim independent report of the Wolfson Centre's findings:
“In mid-2012 the Wolfson Centre were commissioned to carry out tests on REMBE's CLever In-Line flow meter in order to independently verify their claimed repeatable accuracy, which Rembe claim to be a step change in inline flow metering when compared
with the more commonly used impact Weighers. Consequently at the Wolfson Centre we have been testing a REMBE CLD 50 unit on a rig in our pilot plant, to compare its batch totalisation against a calibrated load cell system. Tests with malted barley have been carried out using three different flow rates, ie 22.3, 8.5 and 2.9 tonnes per hour (tph), and with batch sizes from 300 to 630 kg. Bulk density of the material was 709 kg/m3, giving the unit a nominal rated capacity of 35 tph. For the tests at different flow rates, the unit was first calibrated against the load cell, using a test run at the same flow rate used for the tests. 30 to 40 tests were performed with each flow rate, including changing the batch size and looking for drift over a period of up to 2 weeks”. “At 22.3 and 8.5 tph we obtained an average error (deviation from the value indicated by the load cell) of 0.4% of the batch size, across the whole basket of tests. When both calibrated and tested on the same batch size, the average errors went down consistently to around 0.2%”.
“With the very low flow rate (2.9tph which is less than 10% of rated capacity) the average error increased up to 1.0% of the batch size. However it is usual for any instrument to report larger errors (as a percentage of the reading) when working on such a low turn-down”. “Expressed as a percentage of rated through-put, the average errors were around 0.3% at 22.3 tph and 0.1% at the lower throughputs, across the whole range of batch sizes and test conditions”. “The short term repeatability of the instrument (relative standard deviation of the readings over batches of 5 tests at every condition) was in most cases better than 0.1% of the batch size at the 22.3 and 8.5 tph flow rates, rising to 0.9% worst case at the very low flow rate”. “These test results clearly relate to this one free flowing, consistent bulk solid. Tests with other bulk solids of varying densities and sizes are currently in progress. A full analytical report will be provided to REMBE upon completion of further testing”. “Prof Mike Bradley” There are considerable benefits of fitting a dynamic C-LEVER In-Line flow meter/weigher. The compact size means it is easier to install. Lower costs, fewer spares, less downtime. The standard design is stainless steel so it can be used in diverse industries, pharmaceutical, food and beverage, minerals and chemicals. REMBE® LTD have on the ground specialists to review and advise on your specific installation. Go ahead take that leap of faith and contact us. We will even pay for your phone call. Call us now on FREEPHONE 0800 232 1821. Scan the QR Codes below for a product pdf or access to the REMBE® LTD website www.rembe.co.uk
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CEMEX UK invests in a new Precia-Molen VS350 weighbridge at their Angerstein Wharf operation Weighing specialist Precia-Molen of Redditch, Worcestershire has recently replaced an ageing weighbridge with the supply and installation of a new VS350 weighbridge at Angerstein Wharf. Owned and operated by CEMEX UK, Wharf is a marine aggregates facility situated on the south bank of the Thames close to the Millennium Dome in Greenwich, London. Following a replant in 2004 and a further upgrade in 2011 to further increase its supply to the construction market, the site currently hosts a 350tph aggregate washing plant with twin processing lines and also an on-site cement plant. The raw material processed at Angerstein Wharf is obtained from licensed dredging areas in the Thames estuary and Eastern Channel by two dredging vessels operated by CEMEX UK. Unloaded from selfdischarge dredgers three times per week the Angerstein Wharf site is currently processing nearly a million tonnes per annum, from an average 18 hour working day, with approximately 100-150 trucks visiting the site daily. The installation: With such a busy site it was therefore imperative to reduce downtime and disruption to the bare minimum with the installation of the new 16 metre long VS350 weighbridge. With careful planning this was achieved by Precia-Molen engineers commencing installation works late afternoon on the Friday, working through the weekend, with the installation complete by Sunday evening. With the old weighbridge successfully removed by an 80t crane the first task was to extend the existing foundations to accommodate the overhang of the 'big feet'
arrangement of the new VS350 weighbridge. This required the 'feet' to be trimmed down to less than standard size to accommodate the old plinth irregular foundation. Once this had been completed the new weighbridge (supplied in bespoke yellow) was craned into position and secured on the new foundations ready for use. David Whitby - Plant Manager, commented, “Precia-Molen first understood our operation at Angerstein and then planned and implemented a professional installation. We were very pleased with the installation and the new weighbridge” The VS350 weighbridge Finished in high quality paint, the 16 metre long Precia-Molen VS350 heavy - duty steel weighbridge installed at Angerstein Wharf has a total platform weight of 11 tonnes. Featuring a very robust steel platform the weighbridge is constructed with extremely substantial 686 side beams to provide strength and rigidity to the structure, avoiding flexing of the platform. Complete integrity of the structure is ensured by a series of RSJ cross members at 0.5m centres which are welded into the side beams ensuring that the 1.5m deck plate is supported by four cross members. Weighbridge plates are fully welded, with angled deflector plates fitted between the side beams, and the platform, preventing a build-up of debris at the side, or below the platform. The VS350 offers several benefits: • Access to the load cells is from the side, for ease of servicing. • With only four load cells required for a weighbridge up to 18metres, installation time is reduced. • The VS350 can be bolted down to a suitable concrete surface without the need for civil works. Further installations: Since the success of the installation at Angerstein Wharf, CEMEX UK have made further investment in new weighbridges and Precia-Molen have subsequently completed an installation at Gilfach Quarry in Wales and have been awarded a third order from CEMEX UK for the supply and installation of a weighbridge at a brownfield site at Tattershall in Lincolnshire. www.hub-4.com/directory/683
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LOADMASTER a100 debuts at PLANTWORX PLANTWORX 2013 will see RDS Technology debuting the new LOADMASTER a100 on-board weighing system that is described by the UK based manufacturer as being the new industry benchmark in terms of accuracy and ease of use in difficult conditions and terrains.
measuring the angle of the main boom. An additional sensor compensates for oil temperature.
The RDS LOADMASTER a100 is an all-new CAN based system combining cutting edge sensor technology and signal processing techniques providing precise and consistent weight information.
SQL database capability with up to 8 reference fields including 200 products, 2000 customers, 1000 locations, hauliers, trucks & destinations and up to 20 drivers. There is a blend facility with up to 20 mixes each comprising up to 30 products.
With the ever increasing focus on productivity, LOADMASTER a100 has been designed to operate within the fastest loading environments and toughest of conditions compensating for uneven, sloped ground and restricted loading areas reducing cycle times and maximising tons per hour performance. Loading correctly first time eradicates return trips to the stockpile reducing vehicle movement, fuel usage and machine & tyre wear. The new RDS LOADMASTER a100 uses a 7� colour, resistive touch screen display and additional physical keys providing a modern and ergonomic operator interface. Suitable for use with up to 10 different attachments e.g. buckets or forks, the system can be retrofitted onto wheeled, telescopic and tractor type loaders. The system continually measures hydraulic pressure using up to 4 sensors. The pressure signals are captured and filtered through a weighing 'arc' provided by inclination sensors
All signals are processed in the RDS Smart Box and the resultant weight calculation is sent to the terminal mounted in the cabin.
Video input for switching head unit into reversing camera mode removes the need for additional screen, releasing valuable cab space. Also making its Plantworx debut will be the Loadmaster iX range of on-board weighing systems which benefit from additional standard features including temperature compensation enhancing system performance particularly on machines with a wide variation in operating temperature and angle compensation providing an additional level of precision beneficial on most sites and not only those with obvious slopes. In addition the Loadmaster iX range offers effective management of weighing data. The Loadmaster 8000iX has an integral SD card port for the fast and efficient transfer of data between loader and weighbridge or office PC and enables pre-registered customer reference data to be uploaded directly to the instrument. www.hub-4.com/directory/710
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Top safety accreditation Local business Crosby Weighing has been awarded accreditation from Safecontractor for its commitment to achieving excellence in health and safety. Safecontractor is a leading third party accreditation scheme which recognises very high standards in health and safety management amongst UK contractors. Crosby Weighing is principally involved in the service and maintenance sector, specialising in services to all types of industry providing weighing equipment sales, hire, calibration, service and repair. The company's application for safecontractor accreditation was driven by the need for a uniform standard across the business. “We are delighted to have achieved this accreditation which should help us propel the business forward and achieve our goal of becoming the premier provider of scales and weighing equipment and services in the North East” Safecontractor accreditation will enhance the company's ability to attract new contracts and its commitment to safety will be viewed positively by its insurers when the company liability policy is up for renewal. Safecontractor is applicable to most sectors although it is particularly relevant to food manufacture, property, facilities management, retail and leisure sectors, all of which are big users of contracted services. John Kinge, technical director of safecontractor said, "Major organisations simply cannot afford to run the risk of employing contractors who are not able to prove that they have sound health and safety policies in place." "More companies need to understand the importance of adopting good risk management in the way that Crosby Weighing has done. The firm's high standard has set an example which hopefully will be followed by other companies within the sector. Safecontractor plays a vital role in supporting our clients in meeting their compliance needs, whilst working with their contractors as they progress through the accreditation process.” Under the safecontractor scheme, businesses undergo a vetting process which examines health and safety procedures and their track record for safe practice. Those companies meeting the high standard are included on a database, which is accessible to registered users only via a website. Client-organisations who sign up to the scheme can access the database, enabling them to vet potential contractors before they even set foot on site. These clients agree that, as users of the scheme, they will engage only those who have received accreditation. Over one hundred and seventy major nation-wide businesses, from several key sectors, have signed up to use the scheme when selecting contractors for services such as building, cleaning, maintenance, refurbishment or electrical and mechanical work.
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WEIGHBRIDGE MANAGEMENT SYSTEMS GeneSYS™ Enterprise Software • Weighbridges • Driver operation • Hopperscales • Software
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United Kingdom Ireland +44 (0)1527 590320 +353 (0)1 835 3084 sales@preciamolen.co.uk sales@preciamolen.ie
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Caveat emptor potential weighbridge buyers should consider a number of important factors Accurate weight data collection is a vital function within the quarrying, solids handling, recycling and energy from waste industries. Weighbridge management systems play a pivotal role in providing this information; acting as critical control points for vehicles delivering and collecting materials from sites. Over the past five years dramatic changes have occurred; changing the way weighbridge systems are required to operate and how they integrate with peripheral vehicle control equipment and established management software systems. However, there is evidence that performance, reliability and functionality are being compromised through the emergence of lower priced weighbridge systems with questionable long term credentials. Although these may seem initially attractive, the consequences of buying on price alone can be very problematic and expensive. So what are the critical design and operational issues which potential purchasers of weighbridge systems should consider from the outset?. As Weightron Bilanciai's Sales Director Emlyn Roberts explains, three distinct areas need to be considered: • The design and build of the weighbridge itself;
Load Cells The load cells and their associated mounting hardware are considered to be the most crucial part of the weighbridge and are required to work under a range of harsh and challenging environments. Therefore design and application optimisation for these essential components is crucial; not only for performance, but also for long term reliability. Of all the designs, clear evidence from the field shows that compact stainless steel canister load cells, together with well-designed rocker mounting assemblies provide the optimum solution for weighbridges. More cumbersome single ended bending beam load cells or vulnerable double ended shear beams with ball bearing mountings are more likely to fail and generally require more ongoing maintenance. It should be remembered that weighbridge decks can be subject to relatively large expansion-contractions, which affect the load introduction angles and this places further importance on the requirement for well designed load cells and mounting assemblies. Instrumentation Traditional weighbridge instrumentation has developed significantly over the past two to three years. Intuitive touch screen terminals have replaced standard weight indicators and provide a wealth of operational and management features. End users should explore the future proof capabilities of instrumentation and investigate how easy it is to set up fundamental features such as databases and libraries. Driver terminals must be capable of operating with the wide array of recognition technologies such as RFID, magnetic and voice activation.
Software • The pedigree of key measurement chain Today's weighbridge systems are expected to seamlessly integrate with an components (load cells and instrumentation); array of management software systems including SAP, Sage, Microsoft Dynamics and J D Edwards. However, although system functionality for a • Software functionality and software specific project may appear to be well defined at the outset, functional integration. design specifications invariably change throughout a project. As a result it To ensure optimum system compatibility, there is therefore beneficial for the weighbridge supplier to take responsibility are distinct advantages for the customer if the not just for the weighbridge software, but also for the all-important weighbridge supplier is responsible for the interface between the weighbridge system and the overall plant design and manufacture of all critical management system. The use of third party software suppliers, who have equipment and software in these areas. This little or no knowledge of weighing, can turn out to be more complicated provides practical and efficient single source and expensive in the long run. In parallel the weighbridge software must system responsibility. In addition purchasers be fully compatible with the growing range of peripheral equipment should look at the level of after sales support a including automatic number plate cameras, control barriers, traffic lights supplier can offer, together with their quality and card readers. system accreditation and relevant trade Service and Support association membership. Effective rapid response support is essential for weighbridges to minimise Weighbridges downtime. This is far easier if the original supplier has supplied and Weighbridges may seem to be merely pieces installed the complete system and also has readily available trained of metal or concrete, but sound mechanical engineers. design and build procedures are essential both for performance and longevity. In parallel, well Conclusion designed foundations and vehicle approach As weighbridge systems become demanding and operationally complex, areas play a vital role. Cutting corners with the pitfalls of buying on price increase. It is recognised that cost is an factors such as steel quality, weld integrity or important factor, but the apparent advantages of initial low prices can surface finish may reduce prices, but this can soon be lost through unreliability and operational limitations. have a detrimental effect on overall reliability and longevity. www.hub-4.com/directory/2273
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Shering Weighing - Proves that Quality Does Matter Shering Weighing is a family owned business focused on designing and manufacturing the world's finest weighbridges. Shering have been at the forefront of weighbridge manufacturing since our foundation in 1946 and are responsible for all the major advances in weighbridge technology. All our weighbridges and associated equipment are British made and manufactured at our headquarters in Dunfermline, Fife, Scotland. Our global client base has and continues to experience significant growth as a result of maintaining our high quality standards in what is recognised as a very price sensitive market. As a result of our continued success, Shering Weighing were approached by The Daily Telegraph who commissioned a documentary based on the company's business model of unrivalled quality and technology. Similarly, Sky Television aired a programme on Shering Weighing highlighting 'Best Practice in Manufacturing'. Such recognition has significantly enhanced our global profile helping us to maintain our status of producing weighbridges which are built to last and offer world-class innovation in their construction. Shering Weighbridge designs focus on strength, reliability, longevity, resilience and accuracy incorporating exclusive patented technologies which provide real additional benefits to our customers manifested in exceptional warranties on the deck and vital components such as the load cells. The complete Shering package of quality, technology, service and warranties also provide our customers with exceptionally low cost of ownership and peace of mind. We supply and install our equipment including software, hardware and traffic management not only for individual site requirements, but also for specialist projects such as Waste Transfer Stations, Energy from Waste Plants, Material Recycling Facilities and Anaerobic Digestion Plants. For more information on our weighbridges, weighbridge software, and associated weighbridge equipment call our Head Office on 01383 621 505 or e-mail sales@shering.com www.hub-4.com/directory/772
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Weighing Systems Feature
New Weighing Website from Avery Weigh-Tronix Organisations seeking information about weighing should take a look at the new Avery WeighTronix web site, www.averyweightronix.com. The new site is simple to use and navigate. The product selector enables users to find the right weighing solution for their needs while the product comparator tool allows you to compare products by their key features. Product literature is also simple to find along with a range of supplementary information including details of complimentary products and accessories, specification sheets, case studies and videos. The site features a host of information on weighbridges and peripheral equipment, as well as floor scales, bench scales and an extensive portfolio of other weighing equipment. For more information, visit www.averyweigh-tronix.com, call 0845 307 0314 or email info@awtxglobal.com www.hub-4.com/directory/6127
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Weighing Systems Feature
Schenck Process supply new train weighing system for Hanson Cement
Completed installation of new rail weigh bridge
When Hanson Cement, part of Heidelberg Cement group, considered replacing their existing and underperforming train weighing system they approached Schenck Process, specialists in static and dynamic weighing technology and a process solutions provider for the Cement industry. David Holgate, Works Engineering Manager for Hanson Cement, said that the old rail weighing system was unreliable, preventing reliable weighing of rail cars being loaded with OPC (Ordinary Portland Cement) for transportation and distribution to Scotland and the south of England for final distribution by road to their customer base. “Due to the unreliability of the system, many of the rail cars were under filled to prevent excess train weight exceeding the legal rail freight limit, set by network rail. This was a costly and uneconomical exercise, as well as poor utilization of their rail transportation system” stated David Holgate. When Hanson Cement first approached Schenck Process, their brief was to have a solution that was “reliable, accurate and cost effective” and one that could be adapted to operate utilising their existing loading system and within the existing confines of their rail loading facility at their Ribblesdale works, near Clitheroe, Lancashire. The initial assessment by Schenck Process was to fully understand their clients existing problems, understand the type of rail car to be filled and establish how the proposed solution would need to fit and work within the confines of their existing load-out station. The Schenck Process design team proposed a static weighing solution based on this assessment. This solution would allow the system to utilise three individual weigh platforms and having the facility to weigh as one weighbridge, if required. The design had to overcome the problems of being able to fill any one of two types of rail cars, one a twin Bogie rail car with a nett capacity of 100 tonne (80 tonne working capacity) and a single Bogie, 50 tonne capacity (38 tonne Working capacity) both with the facility to be filled, utilising the existing twin out-loading spouts.
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Weigh bridge pit with location platforms for load cells
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Weighing Systems Feature
Tanker fill train loading station
The final system design was for the supply of three in-ground weigh platforms, measuring 5m x 3m and 6m x 3m and 5m x 3m. Each platform was fitted with 4 load cells per platform, giving an overall length of 16 meters and was controlled and monitored using the Schenck Process DISOBOX® and DISOMAT® system controller. These units enable the facility to switch between each platforms and measure individual weight measurement or the total weight. Filling of the trucks would be by the existing outlet spouts. This allowed the operator to select between each weigh bridge as to which type of rail car was to be filled. The system would automatically tare each rail car arrival on the weighbridge and provide a tare weight record. Upon the preset full set point being reached during filling, a signal to stop filling would be given and the feed supply would stop. After a short time delay to allow for any in flight material and settling of material in the rail car, a final gross weight would be recorded. The operator would then have the facility to print out the individual weight records or a total weight of the train on completion of the filling of all the rail cars. Another consideration that the design team had to overcome was the low head room under the twin silos and how the 8 tonne platforms could be manoeuvred and installed safely into position above the pre¬constructed in ground pit. RMB Contractors were commissioned to construct the concrete pit which the platforms would be lowered into as they provided a full design and build package. John Snowdon, Operation Director for RMB Contractors, said the drawing provided by Schenck allowed an easy build program “Schenck Process provided a connection plate which was installed and allowed the existing track to be levelled with the weighbridge track. This meant the construction phase went very well with the concrete cast in one go with no other modifications or alterations were required.” The concrete platforms were also designed and manufactured by Schenck Process. Within the design of each weighbridge, Schenck Process design engineers had included for built-in inspection points by means of access man holes and the facility of preset lifting points to facilitate ease of installation. The system has provided Hanson Cement with a totally reliable plant that has had no downtime since being commissioned in late 2011. The new system has also improved train movement and logistics with an increased number of trains entering the site weekly and delivering Hanson Cement to their distribution points within the UK.
Installation of the weigh bridge
David Holgate, Works Engineering Manager stated that “the system now installed exceeded all our expectations and much more. The system has provided a very accurate method of rail loading and rail car weighing as well as increasing the efficiency of the loading operation.” www.hub-4.com/directory/758
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